g - ALU-WEB.DE

Transcription

g - ALU-WEB.DE

Special: Aluminium
smelting industry
Innovative energy
and fluoride recovery
Improvements for
the operation of
anode baking furnaces
Modelling cathode cooling
after power shutdown
ECL
Improvement of thickness
tolerances for a two-stand
aluminium cold rolling mill
Volume 88 · January / February 2012
International Journal for Industry, Research and Application
Aluminium market outlook
1/2
Compact type remelt
State-of-the-art Scrap Recycling
Leading technology in the aluminum casthouse
There are many benefits in one-stop-shopping of industrial goods. At Hertwich Engineering we provide customer
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service life of equipment. We design and build plants to
meet both, our own stringent standards and individual
customers specifications. Based on many years of experience, we cover the full range of equipment in a modern
aluminum casthouse.
Compact type remelt plant
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Most efficient installation for recycling of inhouse and
purchased scrap
One single fully automated process, starting with
charging of scrap and finishing with homogenized billets,
ready for extruding or forging
Lowest labor costs, one to two operators per shift only
Special design for remelting scrap contaminated with
paint, plastic or oil, also with chip melting system available
Optionally equipped with vertical DC caster
Capacity 2,000 to 30,000 tons/year
More than 25 plants installed
HERTWICH ENGINEERING GMBH
Weinbergerstrasse 6
5280 Braunau, Austria
Phone: +43 (0) 7722 806-0
Fax:
+43 (0) 7722 806-122
E-mail: [email protected]
Internet: www.hertwich.com
EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Aluminiumnachfrage bleibt hoch
Demand for aluminium stays high
ALUMINIUM · 1-2/2012
Nach dem sehr kräftigen Wachstum von 5,1
Prozent 2010 dürfte die globale Wirtschaftsleistung 2011 nur noch um etwa 3,8 Prozent
gestiegen sein. Für 2012 erwarten alle Wirtschaftsanalysten eine weitere Abschwächung
der Weltproduktion. Lediglich über das Ausmaß der Bremsspur gehen die Meinungen auseinander. Dem Prinzip Hoffnung folgend wird
jedoch für 2013 wieder ein Anziehen der globalen Produktion vorausgesagt. Genährt wird
diese Hoffnung davon, dass Europa in eine
nur milde Rezession fällt, die USA moderat
wächst und die Dynamik in den Schwellenländern anhält. Dennoch birgt das laufende Jahr
zahlreiche alte und neue Unwägbarkeiten und
Herausforderungen. Die Stichworte lauten:
Staatsschuldenkrise in Europa und den USA,
Handlungsfähigkeit der US-Administration
im Wahljahr, Ölembargo gegen den Iran und
seine Folgen.
Trotzdem ist die Stimmung in der Industrie nicht durchweg negativ, auch nicht in der
Aluminiumindustrie. Alcoa-Boss Klaus Kleinfeld hat sich bei der Vorstellung der jüngsten
Quartalszahlen optimistisch gezeigt, was die
Aluminiumnachfrage betrifft. Er erwartet für
das aktuelle Jahr eine Wachstumsrate von sieben Prozent. Der Zuwachs wäre damit zwar
niedriger als 2011 und 2010 (10% bzw. 13%),
aber dennoch bemerkenswert hoch. Kleinfeld
steht mit seiner Einschätzung nicht alleine da;
auch andere Konzernchefs gehen davon aus,
dass die kurzfristige Marktnachfrage nach
Aluminium überdurchschnittlich steigt. Die
mittel- und langfristige Entwicklung sieht die
Branche ohnehin in rosigen Farben.
Angetrieben wird diese aktuelle Nachfrage
vor allem aus dem Transportsektor, besonders
aus dem Flugzeug- und Automobilbau, gefolgt
von den Zielmärkten Bau und Verpackung.
Dies und die inzwischen einsetzenden Kürr
zungen bei der Aluminiumproduktion führen
nach Einschätzung von Kleinfeld zu einer
globalen Angebotslücke von etwa 600.000
Tonnen Primäraluminium in diesem Jahr.
Das sollte eine stabilisierende Wirkung auf
den Aluminiumpreis ausüben und die Talfahrt
seit April 2011 vielleicht beenden können.
Doch gehen die Erwartungen der Analysten
über die weitere Entwicklung des Aluminiumpreises weit auseinander (s. Ausblick auf den
Aluminiummarkt, Seite 19-24).
Wie in den vergangenen Jahren widmet
sich die Jan./Febr.-Ausgabe der ALUMINIUM
traditionell der Hüttenaluminiumindustrie
und ihren Ausrüstern. Auch diesmal konnten
wieder eine Reihe hoch interessanter, technisch orientierter Beiträge eingesammelt werr
den, die zeigen, dass es in der Branche keinen
technischen Stillstand gibt.
After the very robust growth of 5.1 percent
in 2010 the world’s economic performance
is likely to have risen farther by only about
3.8 percent during 2011, the year just ended.
For 2012 all economic analysts anticipate a
continuing downturn of world production:
opinions differ only about how severe this
will be. Driven by a spirit of hope, however,
a recovery of global production is forecast for
the following year, 2013. That hope is nourished by the expectation that the recession in
Europe is only mild, moderate growth is taking
place in the United States, and the dynamic
is persisting in developing countries. Yet, the
current year harbours many old and new uncertainties and challenges. The key words are:
national debt crises in Europe and the USA,
the US Administration’s freedom of action in
an election year, the oil embargo against Iran
and it consequences.
Despite all that the mood in industry is
not all gloomy and the same is true in the
aluminium industry. When presenting the
latest quarterly figures, Alcoa boss Klaus
Kleinfeld waxed optimistic about the demand
for aluminium. For this year he anticipates
growth of seven percent and although this
would indeed be lower than in 2011 and 2010
(with 10% and 13%, respectively), it is still
remarkably high. Mr Kleinfeld is not alone in
his estimate: the CEOs of other aluminium
groups too are expecting the short-term market demand for aluminium to increase at an
above-average rate. As things stand, the sector views the medium- and long-term development in a rosy light.
The current demand level is driven above
all by the transport sector, especially aircraft
and automotive engineering, followed by
the target markets of building and packaging.
This, together with the aluminium production
cutbacks occurring meanwhile, will in Kleinfeld’s view lead to a global supply shortfall of
around 600,000 tonnes of primary aluminium
during the course of this year. That is likely
to have a stabilising effect on the aluminium
price and could well be able to bring the
decline since April 2011 to an end. Yet, the
expectations of analysts about the further development of aluminium prices are widely different (see Aluminium market outlook, pages
19-24).
As in previous years, the January / February issue of ALUMINIUM is traditionally
devoted to the aluminium smelting industry
and its suppliers. This time too a number of
highly interesting and technically orientated
contributions have been assembled, which
demonstrate that there is no technical standstill in our industry.
3
I N H A LT
EDITORIAL
A l umi n i u mn a chfra ge b l e i b t h o ch • De ma n d fo r a l u mi n i u m stay s high ... 3
A KT U E L L E S • N E W S I N B R I E F
En e rgie i n t e n s ive In du st ri e st ab i l i s i e rt St ro mn e t z e .............................. 6
A l e ri s b a u t Gi e ß e re i fü r Al -Li -Le gi e ru n ge n ........................................ 6
A l c o a c u t s gl o b a l c a p a c i t y b y 12 p e rc e n t .......................................... 7
A l e ri s b u i l ds c a st i n g fa c i l i t y fo r a l u mi n i u m-l i t h i u m a l l o ys .................... 7
M e ta l l gi e ß e re i Sch e e f – P ro du k t i o n s e rwe i t e ru n g i n Bra n de nburg ........ . 8
M a g n a a c qu i re s BDW c a st i n gs o p e ra t i o n s ......................................... 9
Ko b e St e e l t o fo rm a l u mi n i u m jo i n t ve n t u re i n Ch i n a ......................... 9
SM S: Auft ra gs e i n ga n g 2 011 ü b e r Vo rja h re s n i ve au ............................. 10
11. Umfo rmt e ch n i s ch e s Ko l l o qu i u m Da rmst a dt , 6 ./ 7. Mä rz 2012 .......... 10
TC Pri s ma – a p owe rfu l ma t e ri a l p re c i p i t a t i o n mo de l l i n g s of tware ....... 11
26
6 th Mi ddl e E a st Al u mi n i u m 2 012 Co n fe re n c e .................................... 11
WIRTSCHAFT • ECONOMICS
A l umi n i u mpre i s e ......................................................................... 12
Pro d u k t i o n s dat e n de r de u t s ch e n Al u mi n i u mi n du st ri e ......................... 14
A ra ba l 2 011 fo c u s i n g o n O ma n’s a l u mi n i u m i n du st ry ......................... 16
A l umi n i u m ma rke t o u t l o o k – a ye a r o f u n c e rt a i n t y a n d ch allenge ....... 19
A L U M I N I U M S M E LT I N G I N D U S T R Y
32
TM S 2 012 – wi de ra n ge o f t e ch n i c a l s ymp o s i a .................................24
Duba l p ro p ri e t a ry t e ch n o l o gy l i c e n s e d t o E ma l P h a s e II .....................26
S h ap e d c a t h o de fo r t h e mi n i mi s a t i o n o f t h e
Ha l l -Hé ro u l t p ro c e s s s p e c i fi c e n e rgy c o n s u mp t i o n .............................28
Pre c i s i o n p o t fe e di n g fo r b e t t e r e n vi ro n me n t a l p ro t e c t i o n .................32
Tre nds i n mo de rn re c t i fi e rs – e n e rgy e ffi c i e n c y a n d ava i l a bility ...........34
I n n ova t i ve e n e rgy a n d fl u o ri de re c ove ry ..........................................39
E C L – re n own e d e qu i p me n t s u p p l i e r
t o t h e p ri ma ry a l u mi n i u m i n du st ry .................................................44
4
I m p rove me n t s fo r t h e o p e ra t i o n o f a n o de b a k i n g fu rn a c e s .................46
Te st i n g c e l l c o n t ro l l e r a l go ri t h ms u s i n g a dyn a mi c c e l l s i mulator .........50
Der Aluminium-Branchentreff
des Giesel Verlags: www.alu-web.de
4
Te st i n g o f c a rb o n ma t e ri a l s fo r re s e a rch a n d i n du st ri a l p u rposes .........55
CONTENTS
Anode handling and cleaning systems for modern aluminium smelters ......59
S m e l t er l ogi st i c s up g ra d e . . . . . . . . . . . . . . . . . . . . . ........................................ 61
A l l i a n ces i n t h e a l um i n i um i n d ust r y . . . . . . . . ........................................63
Mode l l i ng ca t h o d e c o o l i n g a f t e r p owe r s hu t down ............................65
A u m u nd cool i n g c o n ve yo r f o r h o t b a t h m a t e ri a l ...............................68
G A P E ng i neer i n g – a n e w g l o b a l s up p l i e r
of a l u m i ni u m c a st i n g t e ch n o l o g i e s . . . . . . . . . ........................................ 71
T E CH N O LO G I E • T E CH N O LO GY
Ve r besser u n ge n d e r Di cke n t o l e ran z e n an e i n e m z we i ge rü st ig e n
A l u m i ni u m - Kal t wa l z we r k • I m p rove m e n t o f t h i ck n e s s t o l e ra n c e s
f or a t wo- st a n d a l um i n i um c o l d ro l l i n g mi l l .....................................73
M i croS t re a m - S t rö mun g s s ch l e ife n für p rä z is e E n db e a rb e i t u n g
Mi croS t re a m fl ow g r i n d i n g f o r h i g h - p re c i s i o n fi n i s h ma ch i n i n g ...........78
A N W E N D U N G • A P P L I C AT I O N
D er neu e M erc e d e s - B e n z S L s e t z t a uf A l um i n i u m
T h e new M erc e d e s - B e n z S L – a l mo st e n t i re l y ma de o f a l u mi n i u m .......80
This issue contains
an enclosure from
GDA Gesamtverband
der Aluminiumindustrie e.V.
to which we draw
your kind attention.
C O M PA N Y N E W S W O R L D W I D E
Inserenten dieser Ausgabe
A l u m i ni u m sme l t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................82
B a u x i t e a n d a l umi n a . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................83
R ecycl i n g a n d s e c o n d ar y s m e l t i n g . . . . . . . . . . ........................................84
Al u m i n i u m semi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................84
List of advertisers
ABB Switzerland
47
Buss AG, Switzerland
49
Buss ChemTech AG, Switzerland
35
Coiltec Maschinenvertriebs GmbH
9
CRU Events, UK
21
O n t h e m ove .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................85
Drache Umwelttechnik GmbH
27
Dubai Aluminium Co. Ltd, UAE
15
Su ppl i e r s . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................86
ECL, France
23
Edimet S.p.a., Italy
23
FLSmidth Hamburg GmbH
29
Glama Maschinenbau GmbH
25
RESEARCH
D a s a e c ( a l u mi n i um e n g i n e e r i n g c e n t e r ) i n Aa ch e n – We l t we i t
größtes Hochschulzentrum für Aluminiumforschung und -lehre, Teil I .......87
D O C U M E N TAT I O N
Hertwich Engineering GmbH, Austria
41
Inotherm Industrieofenund Wärmetechnik GmbH
65
Messe Düsseldorf GmbH
17
Micro-Epsilon Messtechnik
GmbH & Co. KG
75
R&D Carbon Ltd, Switzerland
Pa t e n te . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................89
I m pre ssu m • I mp r i n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 105
Vor scha u • P re vi e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................... . 106
B E Z U G S Q U E L L E N V E R Z E I C H N I S • S U P P L I E R S D I R E C T O R Y .....92
2
Innovatherm Prof. Dr. Leisenberg
GmbH & Co. KG
Reed Exhibition China
53
107
Rösler Oberflächen GmbH
11
SGL Carbon GmbH
31
SMS Siemag Aktiengesellschaft
108
Storvik AS, Norway
45
Thermo-Calc Software, Sweden
33
Wagstaff Inc., USA
13
5
AKTUELLES
Energieintensive Industrie stabilisiert Stromnetze
Die energieintensiven Industrien haben Be- würde. Sie verweisen darauf, dass nur rund mit tragen sie erheblich zur Netzstabilität bei
hauptungen zur teilweisen Befreiung von Netz- 20 statt mehrere Hundert Unternehmen unter und haben so sogar eine kostendämpfende
entgelten einem „Faktencheck“ unterzogen, die Ausnahmeregelung fallen und die Mehrr Wirkung auf die Netznutzung, von der alle
um falsche oder unvollständige Informationen kosten für den Endverbraucher bei 0,1 Cent je Stromnutzer profitieren. Würden die großen
Kilowattstunde liegen. Die energieintensiven Stromabnehmer die Netze so unregelmäßig
in der Berichterstattung zurechtzurücken.
So wird in dem Branchenstatement die Industrien spielen damit nur eine untergeord- nutzen wie Privathaushalte (starke Nutzung
Behauptung zurückgewiesen, bei
tagsüber, wenig in der Nacht),
der Verabschiedung des Enerr
wäre der Bedarf an Regelenergie
giepaketes sei „klammheimlich“
zur gleichmäßigen Auslastung
eine Neuregelung der Stromnetzder Netze deutlich höher, so die
entgeltverordnung untergebracht
WVM. Dementsprechend würden
worden. Eine teilweise Befreiung
auch die Netzkosten für alle deutenergieintensiver Unternehmenlich höher liegen.
von den Netzentgelten, so die Err
Vor diesem Hintergrund könwiderung, sei keineswegs neu. Mit
ne von einem „ungerechtfertigten
Bonus“ der energieintensiven
der Novelle des EnergieleitungsUnternehmen keine Rede sein, so
ausbaugesetzes im Jahr 2009
müssen Unternehmen mit einem
der Branchenverband. Die GroßStrombezug von mehr als 7.000
verbraucher seien wegen der staStunden pro Jahr seit 2011 ein
bilisierenden Wirkung, die sie auf
individuelles Netzentgelt entrichdas Stromnetz ausübten, mit der
ten, das mindestens 20 Prozent
Neufassung der Stromnetzentgeltdes regulären Netzentgeltes beverordnung von den Netzentgelträgt. Die Schwelle wurde damit Großverbraucher stabilisieren die Netze durch ihren gleichmäßigen Stromten befreit worden. VoraussetFoto: ALUMINIUM
schon vor Jahren von 50 Prozent bezug, betont die Wirtschaftsvereinigung Metalle (WVM)
zung für die Ausnahmeregelung
auf 20 Prozent abgesenkt. Mit
sei, dass die befreiten UnternehVerabschiedung der Energiewende wurde nete Rolle bei den Strompreiserhöhungen der men mehr als 7.000 Stunden im Jahr (von insbeschlossen, dass Unternehmen mit mehr als jüngsten Zeit, so die Wirtschaftsvereinigung gesamt 8.750 Jahresstunden) und insgesamt
7.000 Stunden Strombezug und einem Strom- Metalle (WVM).
mehr als 10 GWh Strom im Jahr beziehen.
verbrauch von über 10 Gigawattstunden
Auch die Behauptung, die energieinten- Damit seien tatsächlich nur Unternehmen von
rückwirkend ab Januar 2011 vom regulären siven Unternehmen belasteten durch ihren den Ausnahmen berührt, die kontinuierlich
Netzentgelt befreit sind.
hohen Stromverbrauch das Netz besonders sehr viel Strom verbrauchen. Ihre Befreiung
Die energieintensiven Industrien weisen stark, trifft nicht zu. Das Gegenteil sei der von den Netzentgelten sei also kein Bonus,
auch die Behauptung zurück, dass mehrere Fall, betont die WVM. Die Großabnehmer, sondern resultiere aus ihrer wichtigen Rolle
hundert Großverbraucher aus der Industrie so die Erwiderung, sorgten durch ihren gleich- für das Netz, so die Wirtschaftsvereinigung
eine Ausnahme bei den Netzentgelten erhal- mäßigen Strombezug über das ganze Jahr für Metalle.
ten und Strom dadurch für alle anderen teurer eine gleichmäßige Belastung der Netze. Da-
Aleris baut Gießerei
für Al-Li-Legierungen
Aleris wird eine spezielle Gießerei für Aluminium-Lithium-Platten und -Bleche bauen. Die Anlage wird am Standort Koblenz
gebaut; die Produkte sind vor allem für die
Luft- und Raumfahrtbranche bestimmt. Aluminium-Lithium-Legierungen zeichnen sich
durch geringeres Gewicht als herkömmliche
Flugzeuglegierungen bei, ohne die Festigkeit,
Korrosionsbeständigkeit und Ermüdungsbeständigkeit zu beeinträchtigen.
Die neue Anlage wird in der Lage sein, besonders große Blöcke für Tests sowie für die
Serienfertigung von Aluminium-Lithium-Pro-
6
dukten einzusetzen. Das Design der Anlage
wird auch die Entwicklung neuer, konventioneller Legierungen vereinfachen, um den
Kunden modernste und nachhaltige Lösungen
anzubieten. Die Produktion in der neuen Gießerei soll im ersten Quartal 2013 starten.
Bühler integriert Druckk
gussgeschäft in AG
Zum 1. Januar 2012 hat das Technologieunternehmen Bühler sein Druckgussgeschäft, die
Bühler Druckguss AG, in die Bühler AG integriert. Gleichzeitig wurde die deutsche Niederlassung Bühler Druckgiessysteme GmbH
in die Bühler GmbH integriert. Die Integrationsmaßnahmen dienen der Vereinfachung
von Prozessen und Abläufen. Dadurch soll
der Kundennutzen weiter verbessert werden.
Bühler plant, den Standort Deutschland zu
stärken, indem der Verkauf und Kundendienst
ausgebaut wird. Die Geschäftsprozesse in der
Schweiz und in Deutschland wurden der neuen Situation bereits angepasst. Für Kunden
und Lieferanten ändert sich fast nichts, die
bisherigen Ansprechpartner in Verkauf und
Service bleiben bestehen.
Bühler ist in über 140 Ländern tätig und
beschäftigt weltweit rund 7.800 Mitarbeiter.
Im Geschäftsjahr 2010 erwirtschaftete das
Unternehmen einen Umsatz von 1,9 Mrd.
Schweizer Franken.
NEWS IN BRIEF
Alcoa cuts global capacity by 12 percent
Alcoa
Aluminium flagship Alcoa has announced
it will close or curtail about 531,000 tonnes
(12%) of its global smelting capacity, to lower
its position on the global aluminium cost curve
and improve competitiveness. The company
will permanently close its smelter in Tennessee, which was curtailed in 2009, along with
Ingots produced at Alcoa Tennessee
two of the six idled potlines at its Rockdale
smelter in Texas. Together, these closures will
reduce Alcoa’s global smelting capacity of 4.5
million tpy by 291,000 tonnes, which corresponds to seven percent.
Some days later, Alcoa added it would curtail operations at three European aluminium
smelters as part of the capacity cutback. This
applies to the company’s Portovesme smelter
in Italy as well as to the La Coruña and Avilés
smelters in Spain. These facilities are among
the highest-cost producers in the Alcoa system.
At Portovesme, Alcoa will begin the consultation process to permanently close the 150,000
tpy smelter. The La Coruña and Avilés curtailments are planned to be partial and temporary. Capacity at La Coruña and Avilés
is 87,000 and 93,000 tpy, respectively. The
cutbacks of the three European smelters will
reduce Alcoa’s global smelting capacity by an
additional 240,000 tonnes or about five percent, and are expected to be complete by the
first half of 2012.
The curtailments will contribute to Alcoa’s
long-term goal of improving its position on the
world aluminium production cost curve by 10
percentage points and thus increase the company’s competitiveness in the current volatile
aluminium marketplace. Aluminium prices
have fallen more than 27 percent from their
peak in 2011. “These are difficult but necessary steps to improve Alcoa’s competitiveness,
preserve and grow shareholder value and protect jobs in the rest of the Alcoa system,” says
Alcoa chairman and CEO Klaus Kleinfeld.
In addition to the curtailments, Alcoa will
accelerate actions to reduce the escalating cost
of raw materials. Alcoa’s alumina production
will be reduced across the global refining system to reflect the final curtailments in smelting
as well as prevailing market conditions. This
will contribute to the company’s long-term
goal of lowering its position on the world aluminium production cost curve by ten percentage points.
Alcoa announced a loss from continuing
operations of USD193m in Q4 2011 on restructuring charges associated with the closure and curtailment of high-cost production
capacity, lower aluminium prices and continued market weakness. Excluding the net negative impact of restructuring and other special
items, the loss from continuing operations was
USD34m.
Aleris builds casting facility for aluminium-lithium alloys
Aleris will build a specialised casting facility
for aluminium-lithium plate and sheet products. The facility will be built at the company’s
German plant in Koblenz; the products are
destined to meet the needs of the aerospace
market. Aluminium-lithium alloys enable aircraft manufacturers to increase fuel efficiency
through the weight reduction provided by
aluminium while maintaining strength as well
as corrosion and fatigue resistance.
The new facility will be able to cast full-scale
ingots for trials as well as for serial production of aluminium-lithium products. Moreover, the design of the facility will facilitate
the development of new conventional alloys
to provide customers with the most advanced
and sustainable solutions. Production in the
new casting facility is expected to start in the
first quarter of 2013.
New BA president
for Sapa Profiles
The recent years’ rapid growth has made Sapa
the largest aluminium profiles company in the
world. In order to better capitalise on the synergies within the profiles area and streamline
the operation, Sapa Profiles will be organised
as one business area.
New business area president will be John
Thuestad, as from 1 February 2012. He will be
a part of the corporate management team at
Sapa and report to Sapa president and CEO,
Svein Tore Holsether. In addition he will take
on the role as business area president for Profiles Europe. Sapa Profiles will set up its new
head office in Lausanne, Switzerland, and
John Thuestad will re-locate there.
Novelis to invest
USD50m for new Brazil
can stock coating line
Aluminium producer Novelis Inc. will invest
some USD50m to install a coating line for
beverage can end stock at its Brazilian rolling
and recycling complex in Pindamonhangaba,
the company has recently said. In November
last year, Novelis announced plans to invest
USD32m to expand recycling capacity at its
Pindamonhangaba complex, which will nearly
double the plant’s used beverage can (UBC)
recycling capacity from 200,000 to 390,000
tpy. That investment came on top of a previously announced USD300m rolling mill expansion at Pindamonhangaba.
Hydro curtails production
in Kurri Kurri, Australia
In response to low metal prices and the
uncertain market outlook Hydro has decided
to cut production at its Kurri Kurri aluminium
smelter in Australia. This step will be done
by closing Potline 1, representing an annual
production of 60,000 tonnes. The production
line is expected to be fully curtailed in March.
150 jobs will consequently become redundant.
The cost of curtailing Potline 1 is estimated at
approx. USD20 million.
Kurri Kurri, fully owned by Hydro, has
three production lines with a total annual
production capacity of 180,000 tonnes.
7
AKTUELLES
Wechsel im Vorstand
W
der SMS Siemag AG
Kay Mayland, Vorstandsvorsitzender der SMS
Siemag AG und Mitglied der Geschäftsführung der SMS Holding GmbH, ist Ende 2011
wie geplant aus Altersgründen ausgeschieden
und in den Aufsichtsrat der SMS Siemag AG
gewechselt.
Burkhard Dahmen, Vorstandsmitglied
Stahlwerke / Stranggießtechnik der SMS
Siemag, hat mit Wirkung zum 1. Januar
2012 den Vorstandsvorsitz der Gesellschaft
übernommen. Er wird gleichzeitig Mitglied
der Geschäftsführung der SMS Holding. Seine
Nachfolge als Vorstand der SMS Siemag tritt
Guido Kleinschmidt an, bislang Mitglied der
Geschäftsbereichsleitung Stahlwerke /Stranggießtechnik der Gesellschaft.
Alexander Tutsek, Inhaber
der Refratechnik, verstorben
Im September 2011 verstarb im Alter von 84
Jahren Alexander Tutsek, der Inhaber der Refratechnik Feuerfest Gruppe. Alexander Tutsek
baute die 1950 als Steinwerke Feuerfest Karl
Albert gegründete Firma unter dem Namen
Refratechnik zu einem weltweit agierenden
Konzern mit rund 400 Millionen Euro
Jahresumsatz und 1.500 Mitarbeitern aus.
Refratechnik ist heute Weltmarktführer im
Bereich basische Steine und Komplettanlagen
in der Zementindustrie und Systemanbieter
vor allem in der Stahl- und Aluminiumindustrie. Refratechnik hat mit Produktionsstätten
in Deutschland, Spanien und China eine
Jahreskapazität von circa 400.000 Tonnen an
gebrannten Steinen, 50.000 Tonnen an ungeformten Produkten und 120.000 Tonnen MgO
in Kanada.
Alexander Tutsek war bis zuletzt als Vorsitzender der Geschäftsführung der Refratechnik
Holding GmbH aktiv. Die Rechtsnachfolger
sind die gemeinnützige Alexander-TutsekStiftung und eine Familienstiftung. Beide
Stiftungen garantieren als neue Gesellschafter
die Fortführung des Unternehmens im Sinne
von Alexander Tutsek.
Die operativen Geschäfte werden von den
Firmen Refratechnik Cement GmbH in Göttingen, Refratechnik Asia Ltd. in Hongkong,
Refratechnik Steel GmbH in Düsseldorf und
Baymag Inc. in Calgary, Kanada, weitergeführt.
8
Metallgießerei Scheef
Produktionserweiterung in Brandenburg
Die Metallgießerei Scheeff produziert seit
mehr als 50 Jahren im bayerischen Nersingen
Aluminiumguss, durchschnittlich mit jährr
lich zweistelligen Zuwachsraten, wie der geschäftsführende Gesellschafter Manfred Meier betont. Mit der Zeit wurde es in Nersingen
immer schwieriger, den Mengenzuwachs auf
dem vorhandenen Areal zu produzieren. Eine
bereits geplante Werkserweiterung in Thüringen wurde 2008 wegen der allgemeinen Wirtschaftskrise nicht umgesetzt. In einem neuen
Anlauf entschied man sich für die Expansion
im brandenburgischen Hennersdorf.
Die Scheef GmbH wird an diesem Standort mit der Kokillengussfertigung beginnen.
Später soll mit zwei Formanlagen Sandguss
produziert werden, was auch Hallenerweite-
rungen notwendig macht. Außerdem wird derr
zeit eine neue Formanlage installiert, deren
Anlauf im Februar 2012 vorgesehen ist. Diese
Formanlage wird die größte und modernste
Anlage in der Aluminiumgießereibranche sein,
so Meier. Auch die Peripherie wird komplett
modernisiert. Das gesamte Investitionsvolumen beträgt rund 16 Mio. Euro bis 2014.
Die Kunden des Unternehmens wie Audi,
Porsche, VW, MAN, Deutz, Liebherr, Daimler,
Volvo, Scania verlangen nach immer größeren Bauteilen. Ziel von Scheef ist es, in allen
Baugrößen am Markt tätig zu sein. In Hennersdorf ist beabsichtigt, Stückgewichte von 0,5
bis 12 kg zu gießen, in Nersingen richtet man
sich auf größere Gewichte pro Gussteil bis maximal 80 kg ein.
DIN EN 1090 im Fokus
Ausführung von Stahl- und Aluminiumtragwerken
Die europäische Einheit bei Stahl- und Aluminiumbauten rückt näher. Um europaweit auf
einheitliche Standards für Stahl- und Aluminiumtragwerke zurückgreifen zu können, gibt
es die Eurocodes für die Bemessung und DIN
EN 1090 für die Ausführung. Die dreiteilige
europäische Normenreihe DIN EN 1090 wird
ab dem 1. Juli 2012 in ganz Europa verbindlich
gelten und die in Deutschland bisher gültigen
Normen DIN 18800-7 für Stahlbauten und
DIN V 4113-3 für Aluminiumkonstruktionen
ablösen. Bis dahin gilt jedoch eine Koexistenzphase, während der Metallbauten weiterhin
nach den bisherigen nationalen Regeln für die
Bemessung und Ausführung hergestellt werden können. Dennoch sollte man sich schon
jetzt mit den anstehenden Änderungen verr
traut machen. DIN EN 1090 enthält umfangreiche Angaben zur Zertifizierung der werkseigenen Produktionskontrolle. Diese Vorgaben müssen künftig auch solche Metallbaubetriebe berücksichtigen, die bisher der Klasse
A nach DIN 18800-7 zuzuordnen waren.
Die Umstellung auf die europaweit gültige
Norm ist für viele Unternehmen eine große
Herausforderung. Die vorliegende Publikation hilft, die Umstellung erfolgreich zu meistern: Deshalb sind die DVS-Richtlinie 1711
und das DVS-Merkblatt 1712 Bestandteil
dieser Veröffentlichung. Während die DVSRichtlinie 1711 „Voraussetzungen und Verr
fahren für die Zertifizierung von Herstellern
nach DIN EN 1090-1“ enthält, beschreibt das
DVS-Merk-blatt 1712 die „Werkseigene Produktionskontrolle nach DIN EN 1090-1/-2 am
Beispiel eines Anbaubalkons in EXC 1“. DVS
1712 gibt vor allem den Betrieben, die bisher
der Klasse A zugeordnet wurden, Hilfestellung
bei der Umsetzung der Anforderungen an die
werkseigene Produktionskontrolle. Darüber
hinaus finden sich in dieser Veröffentlichung
auch erläuternde Informationen darüber,
welche Metallbauprodukte welcher Ausführungsklasse (EXC) zuzuordnen sind. Auf Initiative des DVS wurden diese Erläuterungen
2010 verfasst und von der Fachkommission
Bautechnik der Bauministerkonferenz in den
DIBt-Mitteilungen bereits publiziert.
Diese Veröffentlichung soll dabei helfen,
auf dem Weg zu einer europäischen Einheit bei
Stahl- und Aluminiumbauten die Orientierung
zu behalten. Es lohnt sich, den Neuerungen
von DIN EN 1090 offen gegenüberzustehen
und sich den Änderungen zu stellen. Denn die
europaweit geltenden Standards machen Produkte und Leistungen messbar und vergleichbar. Die Unternehmen, die sich an diesen Standards orientieren, verbessern ihre Chancen im
europäischen Wettbewerb.
DIN EN 1090 im Fokus: Ausführung von
Stahl- und Aluminiumtragwerken, 56 Seiten,
5 Abb., 14 Tab., ISBN: 978-3-87155-607-4,
erschienen: September 2011, EUR 58,-
NEWS IN BRIEF
Magna acquires BDW castings operations
sales of approximately 160 million euros.
On completion of the transaction, Cosma
will acquire two operations in Germany, one
in Poland and one in Hungary. BDW’s current customers include Volkswagen, Audi,
Porsche, Mercedes-Benz, Ferrari and ZF.
Closing of the transaction is expected to occur
BDW
Cosma, an operating unit of Canadian Magna
International Inc., has signed an agreement
with the shareholders of BDW technologies, pursuant to which Cosma will acquire
BDW’s four operations. BDW is an industry
leader in vacuum high-pressure aluminium
die casting and expects full-year 2011 total
in the first quarter of 2012, subject to obtaining all necessary regulatory approvals including anti-trust approvals.
The acquisition expands and complements
Cosma’s ability to deliver lightweight solutions for complex body-in-white structural
and chassis components in steel, aluminium or
aluminium-steel hybrid to customers around
the world. The combination of Cosma’s
proven record for body structure and chassis
engineering with thin-wall aluminium casting
capabilities will further enhance its position in
the industry. “The technologies gained from
BDW will complement the low-pressure casting capabilities we recently acquired from
Grenville Castings in Ontario, Canada,” said
Horst Prelog, president of Cosma.
Cosma International manufactures a comprehensive range of metal body systems,
components, assemblies and modules including complete vehicle frames, chassis systems
and body-in-white systems using a variety of
innovative processes such as hydroforming,
stamping and roll forming. Cosma International has 47 manufacturing facilities and 25
product development and engineering centres
worldwide.
BDW casting cell with closing force of 3.200 tonnes
Kobe Steel to form aluminium joint venture in China
Kobe Steel has tied up with Jiangsu Alcha Aluminium, a major producer of aluminium rolled
products in China, to expand its aluminium
business. Kobe Steel and Alcha have signed a
letter of intent to establish a joint venture in
Baotou, Inner Mongolia, to produce and sell
aluminium coil and sheet. After conducting a
detailed feasibility study, both companies plan
to sign the final agreement in spring 2012.
The joint venture, which is planned to be
established in January 2013, is envisaged to be
80% owned by Kobe Steel and 20% by Alcha.
Capital investment is earmarked at approx. 40
billion yen (€402m). The company will produce mainly aluminium coil and sheet for automobiles and beverage cans. Production capacity at the joint venture will be 200,000 tpy.
While the company name is yet to be decided,
the operation will be capitalised at 2 billion
RMB (about 24bn yen). Start-up of operations
is anticipated in 2015.
With demand for aluminium sheet in China
rapidly increasing in recent years, Japanese,
US and European customers have accelerated
their push into the Chinese market. Demand
for aluminium sheet for automobiles and beverage cans, which are major products at Kobe
Steel, is anticipated to grow significantly in the
coming years. But only a limited number of
manufacturers in China can currently make
these products as advanced production technology is required.
The new joint venture will produce aluminium sheet in an integrated operation, from
melting and casting to hot and cold rolling. T
the joint venture plans to install state-of-the-
art equipment to produce some of the world’s
largest aluminium coils. Baotou in Inner Mongolia, where the plant will be constructed, is
close to abundant energy resources and has a
skilled workforce. These factors will give the
joint venture a competitive edge, says Kobe.
Listed on the Shenzhen Stock Exchange,
Alcha is a major manufacturer of aluminium
rolled products. The partner companies are
working on starting up the joint venture, with
Alcha assisting in equipment procurement and
permitting.
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9
AKTUELLES
SMS: Auftragseingang 2011 über Vorjahresniveau
Industrieländern. Die Auslastung der Kapazitäten in der SMS-Gruppe ist aufgrund des gestiegenen Auftragsbestands dennoch bis weit
SMS
Der Auftragseingang der SMS group betrug
2011 vorläufigen Zahlen zufolge rund 3,4
Mrd. Euro. Wie Heinrich Weiss, Vorsitzender
SMS Meer Werkstatt in Möchengladbach
der SMS-Gruppe, in einer Unternehmensmeldung erklärte, sei die Zahl der vergabereifen
Projekte noch stabil, doch seit Mitte des letzten Jahres eine zunehmende Zurückhaltung
bei der Auftragsvergabe spürbar – sowohl bei
größeren Projekten in den Entwicklungs- und
Schwellenländern als auch in den klassischen
in 2012 gesichert. Die Zahl der Mitarbeiter in
der SMS group ist durch die Übernahme von
mehr als 90 Prozent der Anteile an der ele-
xis AG, Wenden, und infolge eines weiteren
Mitarbeiteraufbaus in China und Indien auf
rund 10.600 Mitarbeiter angestiegen, das ist
ein Plus von 15 Prozent.
Wie Weiss weiter erklärte, habe SMS die
zurückliegende Zeit genutzt, um die technische Entwicklung weiter zu intensivieren und
Abläufe zu rationalisieren. Nun komme es
darauf an, auch die Herstellkosten durch ferr
tigungsoptimierte Konstruktionen, höhere Effizienz in der Logistik und steigende Produktivität bei Engineering und Fertigung weiter
zu senken. Dazu würden die verabschiedeten
Investitionsprogramme planmäßig fortgeführt.
Dazu gehören auch die 60 Mio. Euro schweren
Investitionen der SMS Meer in den Standort
Mönchengladbach. Dort werden drei Viertel
aller bestehenden Werkzeugmaschinen ausgetauscht. Zudem wird die Schwerlasthalle um
rund 4.000 Quadratmeter Fläche erweitert.
Daneben errichtet die SMS Siemag zurzeit
für rund 20 Mio. Euro eine Werkstatt in der
Nähe von Shanghai, die im Frühjahr 2012
fertiggestellt sein wird. In Hilchenbach, dem
Stammsitz des vor über 140 Jahren gegründeten Familienunternehmens, werden die über
mehrere Jahre angelegten Investitionen von
insgesamt 80 Mio. Euro zur Schaffung einer
der modernsten Schwermaschinenbau-Werkstätten im Laufe dieses Jahres abgeschlossen
sein.
11. Umformtechnisches Kolloquium Darmstadt, 6./7. März 2012
„Flexible Umformtechnik“
Kuka erhält Großauftrag
aus der Autoindustrie
Kuka Systems hat im vierten Quartal 2011 einen Großauftrag zum hochpräzisen Fügen von
Aluminium-Karosseriebauteilen erhalten. Ein
internationaler Premiumhersteller beauftragte die Gesellschaft mit dem Engineering und
Bau sowie der Montage und Inbetriebnahme
von drei automatisierten Produktionszellen.
Der Anlagenbau hat einen Auftragsumfang
im mittleren zweistelligen Millionen-EuroBereich. Auf der Anlage werden Karosserieteile wie Kotflügel und Motorhauben geformt.
Kuka integriert dabei 125 Industrieroboter in
den Zellen und programmiert die Steuerung,
um die Prozessaufgaben wie Clinchen, Kleben
und Falzen der Bauteile in höchster Qualität
zu garantieren.
10
Das Umformtechnische Kolloquium Darmstadt
(UKD) ist eine zweitägige Vortragsveranstaltung,
die traditionsgemäß alle drei Jahre im Frühjahr
in Darmstadt stattfindet. Als Infoveranstaltung
und Kommunikationsplattform richtet sich das
UKD insbesondere an Fach- und Führungskräfte
produktionstechnischer Unternehmen sowie an
Wissenschaftler aus der Produktionstechnik und
angrenzenden Fachgebieten. Referenten aus
Industrie und Forschung berichten in ihren Vorträgen über aktuelle Entwicklungen und Innovationen in der Produktions- und Umformtechnik,
aber auch über die Produktivität eines Unternehmens im Hinblick auf die vom Kunden immer
mehr geforderte Flexibilität in der Produktion.
Das Tagungsprogramm umfasst 20 Vorträge
an vier Halbtagen. Vortragsthemen sind unter
anderem: „Modulares Maschinen- und Vorschub-
system für die Stanztechnik“, „Flexibilisierung
der Fertigung umformtechnisch erzeugter
Bauteile durch prozessangepasste Halbzeuge“,
„Festwalzen mit Minimalmengenschmierung
bei hydrostatischen Werkzeugen“, „Walzprofilieren im Wandel“, „Warmumformung von
Magnesium-Flachprodukten“, „Entwicklung hoch
umformbarer Aluminiumlegierungen für den
Automobilbau“.
Die Vortragslänge beträgt rund 25 Minuten
mit je anschließender Kurzdiskussion. Erwartet
werden rund 200 Teilnehmer aus dem Maschinen- und Anlagenbau, der Automobil- und
Zulieferindustrie sowie von Universitäten und
Verbänden. Veranstaltungsort ist das Lufthansa
Training & Conference Center in Seeheim-Jugenheim. Weitere Informationen unter www.
ukd2012.ptu-darmstadt.de
NEWS IN BRIEF
Call for papers begins for
TC Prisma – a powerful material
precipitation modelling software
the conference parallel to
ALUMINIUM 2012 trade fair Thermo-Calc Software AB and QuesTek In- We’re excited to have partnered with ThermoThe German Aluminium Association GDA
(Gesamtverband der Aluminiumindustrie)
together with Reed Exhibitions are planning
and organising the conference accompanying
the ALUMINIUM 2012 trade fair. Under the
name ‘Aluminium – Material for the Future’
presentations are planned on the subjects of
processes, transport, automotive, surface and
aluminium markets.
Specialists from companies, research institutes and universities are warmly invited to
submit presentations on these subjects. The
submitted contributions will be examined by a
programme committee, which may also permit
other subject areas.
The contributions will be compiled into a
publication and made available. The submission deadline for the abstracts is 23 March
2012.
Details on the call for papers can be found at
www.aluminium-conference.de
novations LLC have jointly developed ‘TCPrisma’, a new user-friendly software package available from Thermo-Calc Software for
modelling precipitation in multi-component
and multi-phase systems, which is used in conjunction with well-established Thermo-Calc
and ‘Dictra’ software. TC-Prisma evaluates
concurrent nucleation, growth and coarsening,
and incorporates key models and algorithms
from QuesTek’s ‘PrecipiCalc’ precipitation
simulation software, which QuesTek has used
as part of its ‘Materials by Design’ technology
to computationally design novel new alloys
such as ‘Ferrium’ M54, S53, C61 and C64 for
use in aerospace, defence, energy, racing and
other industries.
Charlie Kuehmann, QuesTek’s president
and CEO, commented: “The launch of TCPrisma software is very timely given President
Obama’s recent establishment of the Materials Genome Initiative, since TC-Prisma is an
important new tool for materials design engineers to computationally design materials.
Calc Software, a premier leader in scientific
software and databases that involve computational thermodynamics and diffusion-controlled simulations, to accelerate the adoption of
integrated computational materials engineering (i.e. ICME) tools.”
Anders Engström, Thermo-Calc Software’s
president, added: “TC-Prisma is new, robust,
precipitation modelling software built by two
globally-recognised leaders in computational
modelling, analysis and material design, which
significantly enhances Thermo-Calc and Dictra. To develop TC-Prisma we’re pleased to
have partnered with QuesTek and incorporated key aspects of their PrecipiCalc software, since QuesTek is well-known for their
application of computational materials engineering, software and databases to rapidly
design new materials that meet user-defined
needs.”
More information about TC-Prisma at www.
thermocalc.com/TC-Prisma.htm
6th Middle East Aluminium 2012 Conference, 5 to 7 March in Dubai, UAE
The 6th Middle East Aluminium 2012 Conference gathers together the key aluminium producers and downstream fabricators to discuss
the opportunities connected with the massive
expansion of the regional aluminium sector.
Middle East Aluminium 2012 will be discussing the region’s progress towards becoming a leading player in the global aluminium
market through updates on production capac-
ity, dynamic demand and the development of
the downstream business. The comprehensive
agenda will also look at the forward pricing of
aluminium and the market opportunities and
challenges ahead.
Join C-level executives and senior representatives across the aluminium value chain
including aluminium end-users, extruders,
rolling mills, casthouses, smelters, traders,
equipment and technology providers and
consultants at this premium gathering for the
region’s aluminium industry. Key speakers
include representatives from Midal Cables,
Garmco, Balexco, Gulf Aluminium Council,
EAFA, Oman Aluminium Rolling Co., CRU
Group, London Metal Exchange.
More information about the conference at
www.middleeastaluminium.com
03.03.2012, hall 15, booth F 46.
you‘re in good hands ...
... we have all the pieces.
www.rosler.com
BDA5024K58=8B78=6KUKB7>CK1;0BC8=6
Innovative solutions from the world‘s leader in surface finishing
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Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/in % *
Produktion
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Nov
35,9
46,3
52,6
-4,4
158,2
6,1
50,8
11,8
Dez
37,2
42,2
41,7
-1,6
123,4
12,9
31,3
17,7
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37,1
37,7
50,4
9,9
154,9
11,9
44,8
18,2
Feb
33,8
32,2
54,2
6,4
161,1
9,2
47,3
11,1
Mär
37,0
21,9
58,5
1,9
173,7
0,8
53,1
4,0
Apr
35,7
15,1
53,2
4,5
156,6
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47,3
7,4
Mai
37,1
7,9
56,7
5,8
168,3
3,7
56,1
18,3
Jun
35,9
3,3
51,1
-10,0
133,5
-19,3
49,2
-8,4
Jul
36,7
0,5
52,3
5,2
164,9
4,2
50,7
0,4
Aug
37,0
0,3
45,9
-0,3
159,5
-4,8
50,8
5,0
Sep
35,1
-2,3
54,9
2,4
152,2
-5,4
53,8
5,8
Okt
36,1
-2,9
53,5
2,8
148,6
-8,1
49,8
-1,9
Nov
35,2
-1,9
57,0
8,5
152,8
-3,5
53,2
4,7
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
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14
Sekundäraluminium
Press- und Ziehprodukte
ALUMINIUM · 12/2011
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ECONOMY
Conference report
Arabal 2011 focusing on Oman’s aluminium industry
From 13 to 15 November 2011 over 400
delegates from 30 countries attended the
Arabal Conference, held for the first time
in Muscat, the Capital city of the Sultanate of Oman. The participants came
mainly from the aluminium world in Arabia, but from Europe and Asia as well.
The host of this year’s event was Sohar
Aluminium. Under the heading ‘Global
Challenges for Sustainable Growth in
the Aluminium Industry and the Role
of the Gulf Smelters’, the more than 20
lectures dealt mainly with the further development of the aluminium industry in
Arab countries. Held for the first time in
Oman, the Arabal Conference focused on
the growing importance of the aluminium
downstream business in the Sultanate.
Images: Arabal
B. Rieth, Meerbusch
HE Sheikh Saad Bin Mohammad Al Saadi, Minister
of Commerce and Industry in Oman
At present, in Sohar Aluminium the Omanisation policy has achieved a success rate of 70
percent, which is to increase to 85 percent by
2015. This should not only ensure that in the
medium term a job is available for every citizen, but also reduce the country’s dependence
on a foreign workforce. In this connection the
flagship Sohar Aluminium is not just regarded
as an aluminium smelter, but as the centre of
a cluster in which, in the future, 60 percent of
the smelter aluminium produced will be fur-
executive of the group, also stressed the importance of Sohar Aluminium and does not
exclude a possible capacity enlargement there
by 2014. RTA has a close relationship with
Oman through its 20 percent shareholding in
Sohar Aluminium. Globally, RTA anticipates
a yearly aluminium production growth rate of
six percent. A reason for this dynamic growth
is the increasing urbanisation in the economically developing countries, which will go hand
in hand with a rapid increase in demand from
the building, transport and packaging sectors.
In the medium term RTA expects to see a doubling of the present production levels of both
aluminium and copper.
Sohar Aluminium – a benchmark
in the aluminium smelting industry
In his welcoming address HE Sheikh Saad
To the participants in Arabal 2011 and those
Bin Mohammad Al Saadi, Minister of Comwho went on the plant tour of the smelter some
merce and Industry in the host country Oman,
200 km away in Sohar, Sohar Aluminium was
stressed the importance for his country of the
the perfect host. The company was formed
extension of an aluminium industry that inin September 2004 to undertake a landcludes the entire value chain, from smelter
mark greenfield aluminium smelter project
production to further processing. Besides the
in the Sultanate of Oman. Jointly owned by
development of infrastructure, including the
Oman Oil Company (40%), Abu Dhabi Naenlargement of the port of Sohar
tional Energy Company PJSC
and the domestic power generation
– TAQA (40%) and Rio Tinto
industry, it is a particular concern
Alcan (20%), Sohar Aluminium
of the country to create jobs. In
reached full capacity on 19 Febthis respect Oman differs from its
ruary 2009 and some 30 months
neighbours where, at least in the
later celebrated its one-millionth
initial phase, substantial capacitonne of aluminium produced.
ties for the production of smelter
In that time capacity was upaluminium on the basis of cheap
graded from 350,000 to 375,000
energy and foreign workers have
tonnes a year. The total costs for
been created and from there the
this smelter capacity amount to
metal is exported to industrialised
USD2.4 billion.
and developing countries all over
The national importance of
the world for value-adding further
the company is demonstrated by
processing. The Sultanate of Oman
the fact that 56 percent of its anregards its gas and oil reserves as
nual spend is in the local market,
valuable raw material for ensuring The Arabal Conference attracted some 400 delegates from over 30 countries
which equated to USD50 million
its future national prosperity, by
in 2010.
the rational use of which urgently needed jobs ther processed into semis and finished prodSohar Aluminium is supported by an imfor the coming generation should be provided. ucts. Since reaching its full capacity of 375,000 pressive and comprehensive infrastructure.
The proportion of people under 20 years old tonnes a year in February 2009, the plant in Its facilities include one of the world’s fastestthe port city of Sohar has already created growing ports and a power plant and smelter
in Oman is higher than 40 percent.
In the implementation of this strategy – the 1,000 jobs in the area close to the smelter. In which use the latest technology and employ
‘Omanisation’ of the economy – Sohar Alu- addition, a further 2,500 jobs should be cre- the best practices. Within the Port of Sohar the
minium is playing an important part. The aim ated in the downstream sectors.
company has its own dedicated port facility,
of Omanisation is to replace foreign workers
With regard to the global activities of which supports vessels with a capacity of up to
by Omani citizens active in the jobs available. Rio Tinto Alcan (RTA), Jacynthe Côté, chief 75,000 tonnes for receiving raw materials and
16
for exporting primary aluminium. The port facility includes a bulk
material ship unloader with connecting conveyors and a range of
silos for storing alumina (2 x 60,000 t), petroleum coke (2 x 15,000
t) and liquid pitch (2 x 5,000 t).
The Sohar Aluminium Power Plant (SAPP) lies at the core of
Sohar Aluminium’s operations. SAPP is a state of the art 1,000 MW
combined-cycle, captive power plant. It achieves close to 50 percent
efficiency in converting gas energy into electricity and meets the
stringent requirements set out by Oman’s environmental agency
MECA. SAPP is strategically positioned to maximise access to the
region’s plentiful natural gas reserves and to have access to the
Gulf of Oman for cooling water. SAPP excels by achieving high levels of efficiency, reliability and availability of power whilst ensuring
low emissions, operating costs and environmental impact.
Sohar Aluminium operates the world’s longest single potline
with a length of 1.2 km and is the first smelter in the world that uses
Rio Tinto Alcan’s AP36 smelting technology – one of the most energy-efficient and productive smelting technologies commercially
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available. With an operating current of 360 kA which has gradually
been increased to 375 kA, the company produces 375,000 tonnes
of aluminium a year at purities of p1020 and above.
The smelter also has an on-site carbon facility for the production of rods and its own anodes, to ensure maximum efficiency
and availability to the smelter. The Rhodax crusher used on site
has one of the highest production capacities in the world. The casthouse is another source of pride. The company operates an ingot
caster with a throughput of 27 tonnes an hour, which is the world’s
highest known output performance. The casthouse also features a
25-tonnes an hour sow caster.
Sohar Aluminium produces metal in three formats: 23.7-kg ingots, 700-kg sows and liquid metal available to local downstream
partners to reduce energy consumption in subsequent processing.
Aluminium semis, which in the present phase of enlargement cannot yet be absorbed by local markets, are sold by RTA to Asian
markets such as China, Malaysia and Indonesia.
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Sohar Free Zone – Oman’s future aluminium centre
Part of Sohar Aluminium’s overall strategy is to promote and support the establishment of a robust downstream aluminium industry
in Oman, to create added value for primary aluminium and to
develop Oman’s economy, in order to create further employment
and business opportunities.
Two hundred hectares of land adjacent to the smelter site in
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ECONOMY
tonnes a year is on the one hand lower than
the economically viable limit of a conventional
plant consisting of a rolling slab casting unit
and hot and cold rolling mills, but on the other
hand relatively high for the alternative possible use of twinroll casting machines, a different solution was decided upon: the molten
aluminium delivered by the smelter will be
delivered via holding furnaces to a twin-belt
caster. In this it will solidify into strips 2,032
mm wide and 13 to 21 mm thick. The solidified strip will go directly to a hot rolling mill
where it will be reduced down to a thickness
of 1 to 2 mm in an in-line/hot rolling process,
and then coiled. This will then be followed by
the usual cold-rolling process on a four-high
reversing rolling stand with the necessary intermediate and final annealing operations. The
capacity of such an in-line/ hot rolling unit, for
Fata EPC
the Sohar Industrial Estate are set aside for
downstream industry development. In future
up to 60 percent of the annual production capacity of Sohar Aluminium will be sold on to
the local downstream industry. Local companies can take advantage of liquid metal sales
to manufacture all kinds of aluminium products.
Besides aluminium processors such as
OAPIL (aluminium rod and overhead line
conductors), which have already been established in the vicinity of the smelter, from
2014 the Oman Aluminium Rolling Company
(OARC) will be the largest purchaser of molten aluminium. This company, 100%-owned
by Takamul Investment Co., is currently investing USD387 million to build a major aluminium strip-rolling plant with a capacity of
160,000 tonnes a year, a level which should
Schematic layout of the OARC rollling mill
be reached after five years of operation. The
main supplier is Fata EPC in Italy, which is at
the same time acting as the general contractor. For this purpose Fata EPC is enlarging its
establishment if Qatar with an additional location in Oman.
The plant is designed for the production of
strips made from alloys of the 1xxx, 3xxx and
8xxx groups, in widths up to 1,900 mm and
in the thickness range 0.075 1.5 mm in the
form of semi-finished coil products, i.e. foil
stock for converter foil, packaging foil and cable wrap. In addition it will produce finished
coil products such as fin stock and semi-rigid
container foil, for example for aluminium
food containers but also for the construction
of cooling aggregates in the automobile and
building sectors. Further products planned will
be tension-levelled industrial sheet for building products in the thickness range 0.3 to 1.5
mm, and hot strip from 1.5 to 8 mm thick and
up to 1,900 mm wide.
The established strip and foil rolling plant
Garmco in Bahrain, which from the first
showed interest in the project, will undertake
the marketing of OARC products during the
initial phase.
The concept of the plant is worthy of particular attention. Since the capacity of 160,000
18
a cast width of 2,000 mm, certainly amounts to
250,000 to 300,000 tonnes a year. This means
that when the cold rolling and finishing capacities are increased accordingly, the plant can be
adapted for future market developments with
relatively little effort and costs.
Provided in the finishing area are specialised slitting operations, a coil pain line and a
specialised coil coating application.
Aluminium production worldwide
remain on the way to growth
Besides the considerations relevant to Oman,
during the event other matters of current interest in the context of a larger economic area
were also discussed.
Having regard to the present and future
development of the worldwide aluminium
market, even in the Near East it is hardly possible to avoid a glance at the Chinese market. Ultimately, China is a major purchaser of
the primary aluminium produced in the Gulf
area, but it is also a not insignificant supplier
of aluminium finished products. Aluminium
production in China, at any rate in the country’s eastern provinces, is confronted by rising
energy prices. This is one of the reasons why
over the coming few years expansion into the
substantially more favourable North-Western
provinces will take place.
In summary, it was emphasised that despite
all obstacles such as rising prices for energy
and raw materials (alumina), but assisted
by lower capital expenditure of less than
USD2,000 a tonne of aluminium compared
with up to USD4,000 a tonne elsewhere, for
the next several years China will remain the
driving force for the growth of worldwide aluminium production. The fact is, however, that
15 million tonnes of the worldwide production
total of 21 million tonnes planned by 2016 will
be produced by additional smelter capacities
in China. In addition extensive investments
in further processing, namely in new rolling
and extrusion capacities, should not be overlooked. These are making China a net exporter
of aluminium semis. Rather daring forecasts
assume that China will in a few years reach
the same per-capita consumption of aluminium (including the exported fraction) as is now
typical of western industrialised countries.
Very great potential for covering the future
aluminium needs, besides the construction of
new smelters, is seen in the promotion of recycling processes. The International Aluminium
Institute (IAI) expects that in 2020, of the total demands amounting to around 110 million
tonnes of aluminium, about 30 percent will be
covered by recycling. Even in the Gulf, where
the recycling of process scrap and end-of-life
products is still hardly an issue for lack of a
hitherto underdeveloped downstream industry, the concept of recycling is beginning to
gain ground. In this connection a plan was discussed, for building up Oman as a recycling
centre for the whole of the Gulf region. At any
rate, by 2020 the scrap yield is expected to be
about 270,000 tonnes.
With the event held in Muscat, Arabal
showed that this conference is one of the most
important occasions for the international aluminium industry. This also finds expression in
the fact that the event, first held in 1983, no
longer takes place as originally in a two-year
cycle in one or other of the Arabian countries,
but annually since 2010. So the next Arabal
Conference will take place in 2012, in Qatar
in November. The host will then be Qatalum,
the joint venture between Qatar Petroleum
and Norsk Hydro.
Author
Dipl.-Ing. Bernhard Rieth is a marketing specialist
and freelance technical journalist. As proprietor of
Marketing Xpertise Rieth in Meerbusch, Germany,
he advises equipment partners of the NF metals
semis industry on marketing-related matters.
ECONOMY
Aluminium market outlook
A year of uncertainty and challenge
As the European debt crisis is spreading
there were no words of optimism to be
heard during December concerning not
just the European economic outlook for
2012, but for the rest of the world too.
At the beginning of this year, Spain’s
government announced that its budget
deficit in 2011 could be even higher than
the last forecast of 8%. This would imply
additional and continued pressure on
the euro versus US dollar in the coming
months and lead to stagnant or even lower base metals prices. However, support
may come eventually from a rising oil
price which will depend on developments
in Iran, especially after the United States
and the European Union introduced new
sanctions as a reaction to reports that
Iran is progressing with its nuclear programme. In response, Iran has warned
it could shut the strategically important
Strait of Hormuz, a narrow shipping lane
in the Persian Gulf, which would severely
impede oil supplies, and has started testing long-range missiles.
Against this background it is to be expected
that despite a bleak economic outlook, the
Brent oil price will remain volatile and relatively high – around and above USD110
during the first half of 2012 – with the possibility to rise sharply if there
are further threats to shut the
Strait of Hormuz. In this case
base metals prices might get
short-term support from high
oil prices, only to plunge once
the situation over Iran calms
and the world economy becomes even more affected by
high oil prices. 2012 or 2013,
if not both years, would then
turn out to be worse for base
metals prices than in 2011.
Moreover, 2012 would definitely be politically and economically more
challenging than last year, but base metals
prices may bottom out in 2013.
Review of the economic situation
Better than expected latest economic figures
in the USA – the trend of unemployment during December fell to the lowest level in more
than three years – brought a much needed
breath of optimism to the equity markets,
which cheered base metals prices too. The
December 2011 ISM Manufacturing Report,
which tracks the manufacturing activity, heralded good news too: the PMI (Purchasing
Managers Index) climbed from 52.7 index
points in November to 53.9 points in December, which was above the expectations
of analysts polled by Bloomberg. The Index
has remained above the 50-level for twentynine consecutive months, indicating sustainable growth in the manufacturing sector of
the world’s largest economy. The annualised
December PMI corresponds to a 4% increase
in real GDP annually, according to the report
issued by the Institute of Supply Management
early in January.
China’s December PMI rebounded to 50.3
index points, compared with 49 points in November, indicating that the country’s manufacturing activity is expanding. A PMI reading
above 50 demarcates expansion from contraction. However, this rise may be the result of
seasonal bias in the lead-up to the Chinese
Lunar Year, so December’s growth should be
regarded with some caution. In that context,
the sub-index for overall new orders increased
to 46.9 in December from November’s 45, but
also showed falling demand (below 50). New
export orders dipped, reflecting waning de-
mand from the US and Europe, but input costs
incurred by Chinese manufacturers continue
to moderate.
The Euro zone Manufacturing Purchasing
Managers Index rose slightly in December to
46.9 points from November’s 28-month low of
46.4, but still marked a fifth month below the
50 mark that denotes contraction.
Germany made a good start in the new year
G. Djukanovic
G. Djukanovic, Podgorica
with strong manufacturing, consumption and
labour data in Europe’s largest economy. The
closely watched Markit Manufacturing Indicator rose to 48.4 in December, up from 47.9 in
November, reflecting the continued strength
of Germany’s key industrial sector. The Ifo
Confidence Index rose to 107.2 in December,
from 106.6 a month earlier. According to the
Ifo Institute, Germany’s economy will grow by
a meagre 0.4% this year, down from around
3% in 2011, and could slide into recession
if the Euro zone debt crisis deepens. The US
economy may grow by at most 1.5% in the
author’s opinion, despite the latest forecast by
the Federal Reserve that growth would be in
the range of 2.5 to 2.9% in 2012, down from
the 3.3 to 3.7% Fed forecast in June. Lower
GDP growths in Europe and the USA would
negatively affect GDP growth in China, bringing it down to a range of 7 to 8% in 2012 from
around 9% in the last quarter of 2011. In case
of a recession in Europe, economic growth in
China might fall even more.
Due to the European debt crisis, the Euro
will remain under strong pressure in
the coming months, heading towards
1.25 EUR/USD by the second quarter
of 2012. Market participants remain
sceptical in expectation of whether rating agencies will continue to downgrade
European countries, with Slovenia being the last one, something that permanently undermines the Euro.
The European Union summit early
in December ended with an agreement
by 26 of its 27 members to adopt measures aimed at easing the sovereign debt
crisis in the short term and improving
member states’ fiscal positions over the longer
term. Each country’s government will have to
ensure an annual budget deficit of no more
than 0.5% of GDP with automatic fines for
governments that breach a 3% deficit limit.
Leaders in the European parliament have also
proposed a ‘road map’ for common Euro-region bonds in a new European treaty on fiscal
discipline.
©
19
ECONOMY
Aluminium demand slowing
During November 2011, traders announced
that large quantities of aluminium would enter LME warehouses before year-end, which
proved to be the case. LME registered stocks
increased by around 300,000 tonnes in just
four working days in mid-December, ending
the year at 4.97m tonnes which is an all-time
record. However, most of these stocks are still
vember (30 days) was 2.121m tonnes, down
from a revised 2.199m tonnes in October (31
days) but up from 2.057m tonnes in November 2010.
Total world production is expected to
amount to around 44.7m tonnes in 2011, an
increase of some 7% y-o-y, while consumption will expand close to 8% to around 43.8m
tonnes, compared to an increase of around
17% in 2010.
tied up in financing deals of banks. Traders and
analysts estimate that total aluminium inventories around the world stand at about 12m
tonnes, though large quantities have been tied
up in financing deals that were put in place in
2008/09.
Industry experts believe that some 30 to
35% of the world’s smelters are unprofitable with current aluminium prices below
USD2,000/t. What industry experts do not
say is the percentage of those who protect the
selling price by longer term purchasing contracts at levels higher than the current LME
cash price and even higher than their production cost. This partially explains why about a
quarter of world producers are still operating. Another explanation is that until recently
most of the marginal (money losing) producers hoped market conditions would improve
by the end of 2011 so that losses could then
be compensated in the first quarter of 2012.
Latest developments, however, have slashed
such hopes and very soon producers will start
to reduce their production or even close their
smelters.
World primary aluminium production averaged 70,700 tonnes/day in November 2011,
down from a revised average of 70,900 t/day
in October but up from 68,600 t/day in November 2010, according to the International
Aluminium Institute. Total production in No-
The aluminium price will trade in the range
of USD2,000-2,350/t in the next six months,
according to the median estimate of 17 analysts surveyed by Bloomberg in early November.
EUROPE: According to several trading
sources European aluminium orders fell by
around 20% in the fourth quarter of 2011
compared to the same quarter a year earlier,
while aluminium premiums have dropped
25% since mid-2011. Some areas of demand,
such as the packaging and construction industries, have contracted sharply, according
to traders, especially in southern Europe. An
aluminium trader for a large trading house
describes Italy as a ‘disaster zone’. “Everyone
has been having pushback on contracts this
year in the second half,” he said. Traders were
bearish on demand for the first half of 2012
and expect volumes to be lower, although this
estimate might be politically induced and aims
at lowering premiums, traders admit.
Consumers have mostly deferred 2012
orders during the last two months in 2011
due to Europe’s deteriorating outlook which
has led to producers’ metal becoming more
freely available, metals industry sources say.
The producers cleaned up their balance sheets
for the fiscal year-end while most market participants wanted to sell, rarely to buy. This resulted in lower premiums for Western duty-
20
paid aluminium in the Rotterdam warehouse,
quoted mostly in the USD145-165/t range in
mid-December, down from USD200-220/t in
August. Duty unpaid premiums were quoted
at USD100-130/t in that time.
CHINA: China shut down about 630,000
tpy of primary aluminium smelting capacity
in December due to negative margins, the
China Economic Information Centre (CEIC),
which is a unit of the state’s Xinhua news
agency, reported. At least 1.4m tonnes of
annual capacity had already been made idle
before December, taking the total idle capacity to around 2.03m tpy. More cutbacks are
expected if aluminium prices fail to rebound,
the report says. The CEIC put the production
cost of China’s higher-cost aluminium smelters
at Yuan 18,000/t (USD2,185/t), notably those
in the south-western regions, although Chinalco general manager Weiping Xiong gave
the average Chinese production cost as Yuan
16,500/t (USD2,002/t) at a recent industry
conference.
China imported 174,100 tonnes of primary
aluminium between January and November
2011 and exported 76,500 tonnes during the
same period, hence logging a net import of
118,100 tonnes compared with a net import
of 40,300 tonnes for the same 2010 period,
CEIC said. Demand from the semi-finished
sector has remained healthy as semis output
rose 2.5% month-on-month and 9.8% yearon-year to 2.128m tonnes in November.
However, end consumption has shown signs
of softening, especially in the sectors of home
appliances and auto vehicles, coupled with
flattening semis exports, according to CEIC,
Platts reported. Chinese output of primary
aluminium rose 10.2% y-o-y to 16.28m
tonnes in the year to November, slowing from
a 22.6% growth in the same period of 2010.
Production in November was 1.4m tonnes.
NORTH AMERICA: US service centres
shipped 120,800 tonnes of aluminium products during November 2011, a 1.4% decline
from October’s 128,000 tonnes total, but
a 9.5% increase against November 2010.
Aluminium shipments from US centres until November 2011 were 1.392m tonnes, a
15.5% increase against the 2010 period. As
November ended, the centres had aluminium product inventories of 359,500 tonnes, a
3.4% increase against November 2010 inventories and a 0.4% increase against October’s
inventory level. At the current shipping rate,
US service centres have a 3-months supply of
aluminium products, a 5.5% decrease from
November 2010.
In Canada, service centres shipped 13,200
tonnes of aluminium products during Novem-
th
17 World Aluminium
Conference
30 April-2 May 2012, Fairmont, Abu Dhabi, United Arab Emirates
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ECONOMY
ber, a 7.3% rise compared with the October
total of 12,300 tonnes, and an increase of
4.7% compared with the October 2010 result. In the year to November 2011, Canadian
centres shipped 136,700 tonnes of aluminium
products, an 8.3% rise over the corresponding 2010 period. Canada’s centres reported
35,300 tonnes of aluminium in inventory at
the end of November 2011, an increase of
14.0% against November 2010 and a decrease
of 2.9% from October 2011. At the current
shipping rate, this represents 2.7 months of
supply of aluminium, up 8.8% from the corresponding figure in November 2010.
According to data published by the US
Census Bureau, US primary metal producers and metal fabricators registered a sharp
drop in shipments during November compared with October, while inventories fell just
slightly. Over eleven months, primary metals
shipments grew 29.8% and new orders rose
26.1%. Fabricators’ shipping values in November declined 6.3%, with new orders also
down 6%. Meanwhile, shipping values up until November grew 6% and new orders increased by 7.9%. Primary metal inventory
values inched down 0.7% while fabricators
saw that figure fall by just 0.1%. The US
Midwest premium fell to USD7.70 a pound
in early December, down from USD8.20 two
months ago, according to CRU.
JAPAN: Japan’s shipments of rolled aluminium products decreased 6% in November
y-o-y, the sixth straight month of decline as
overseas demand weakened and cut exports.
Supplies to domestic and export markets
dropped to 172,576 tonnes in November
from 183,613 tonnes a year earlier, the Japan
Aluminium Association announced. The pace
of decline accelerated from a 2.8% drop in
October.
Japanese exports of flat-rolled and extruded products slumped 34% in November
after floods in Thailand disrupted the supply
of components and reduced the production
of cars and electric machinery. Aluminium
premiums for Japan’s buyers were down 5%
for the first quarter of 2012 compared to the
previous quarter, and have been mostly set at
USD112/t over the LME cash price. Buyers
pay a premium in addition to the LME cash
price to cover freight and insurance and to reflect regional supply and demand. Japan imports around 2m tpy of primary aluminium.
Aluminium stocks at key ports in Japan –
Yokohama, Nagoya and Osaka – totalled
221,500 tonnes at the end of November, down
6% against the month before, trading house
Marubeni reported.
BRAZIL: Brazilian smelters produced
22
120,200 tonnes of primary aluminium in
November 2011, down 4.9% compared with
November 2010, according to the country’s
national association Abal. Up until November
2011 production was down 6.6% to 1.31m
tonnes. Norsk Hydro’s Albras produced the
highest volume in November, 36,700 tonnes,
down 2.1% year-on-year. CBA came second
with 36,200 tonnes, a 5.5% decrease. Alcoa
produced the same 29,100 tonnes as in November 2010, while BHP Billiton reported a
2.8% increase to 14,600 tonnes. Novelis produced 3,600 tonnes, a drop of 50.7%, since
it closed one of its two smelters in Brazil late
in 2010.
Processed aluminium consumption in Brazil is expected to increase 9.3% y-o-y to reach
1.42m tonnes. For the first three quarters in
2011, consumption reached 1.04m tonnes, up
10.4%. The highest increase came from wire
and cable, which accumulated 120,800 tonnes,
a boost of 85.8%. This leads to the conclusion
that Brazil is switching from copper to aluminium for the national electricity grid and other
uses. Consumption of castings rose 10.9% to
176,500 tonnes in the first nine months of
2011. Sheet and plates rose 4% to 383,200
tonnes, extruded products 3.8% to 214,300
tonnes and foils 1.8% to 66,100 tonnes, all
figures reported by Abal.
On the back of the large increase of aluminium consumption, Abal expects imports to
rise 48% to 399,300 tonnes in 2011. Imports
totalled 305,500 tonnes in the first three quarters of 2011, up 74.7% y-o-y, while exports
fell by 11.4% to 497,600 tonnes in the corresponding period, and are expected to reach
649,200 tonnes, a 14% decrease in 2011. Imports have been rising in Brazil because local
smelters have not been investing in expansion
or greenfield projects, as energy prices are
considered very high in the country. As a consequence, Brazil is soon expected to become a
net importer of primary aluminium.
Alumina price on the decrease
Spot alumina prices and alumina indexes continue to fall, in parallel with the aluminium
price, ending the year at around USD300/t
on a fob basis, with low market activity in expectation of an ongoing decrease of the price.
Some traders expect the price to slip below
USD300/t in January, though China has lately
been a stabilising influence, with several parties expressing potential demand for February
shipments at around USD300/t. European and
Asian consumer sources put buying offers at
USD305-335/t, with the selling interest rangebound at USD340-350/t in recent weeks. Chi-
na’s costlier domestic alumina cargoes and
yuan-denominated trade financing rates have
been fuelling interest in imported alumina,
sources said. Platts Chinese domestic alumina
assessment at Yuan 2,650/t (USD420/t) exworks Henan would have equated to USD325/
t in import parity terms, after taking into account Yuan 80/t in domestic handling costs,
the day’s yuan-dollar exchange rate, 17% in
VAT and USD23/t in freight for 30,000 tonnes
from Western Australia to Qingdao in northern China, for shipment in February.
Chinese alumina production may reach
43.5m tonnes in 2012, which is an 11.5% rise
y-o-y, compared to a gain of 25% to 39m
tonnes expected for 2011, the state research
agency Antaike forecasts. The production capacity of alumina in China may rise 11% to
55m tonnes in 2012, from 49.5m tonnes forecast for 2011. This would finally result in higher imports of bauxite in the following years.
India’s Nalco has finalised its third 2012
alumina term sell tender, comprising 240,000
tonnes at 16.39% of the three-month LME
aluminium price on a fob basis. The Switzerland-based buyer will receive the alumina in
batches between January and December this
year, Ansuman Das, commercial director at
Nalco, told Reuters. Nalco had awarded to
Glencore its first 2012 term contract in October comprising 300,000 tonnes at 16.1% of
the LME 3-month price. The second contract
for 270,000 tonnes went to Standard Bank at
16.2% (source: Platts).
In early November Alcoa announced it
would sell 40% of its alumina production on
spot or index contracts by the end of 2012.
Ship-owners were divided over what they
should consider a reasonable freight rate for
February. One put the market at USD2222.50/t while another one quoted USD23.5024/t. The first source said there was a recent
ECONOMY
prompt fixture done at USD18-19/t; the other
valued the prompt market at USD22-22.50/t,
Platts reported.
Banks’ expectations
Credit Suisse was quite pessimistic in its latest report, forecasting an aluminium price of
USD1,750/t by the end of the first quarter
2012 and USD1,850/t by the end of the year.
The bank stated that “both momentum and
trend indicators have turned negative and hint
at further weakness ahead as persisting deleveraging pressures and deteriorating technicals
may lead the market to undershoot fundamental fair value further”.
Another Swiss investment bank, UBS,
forecasts an average aluminium price in 2012
at USD2,226/t and at USD2,535/t in 2013.
“We see an inevitable deceleration of global
growth in H1 2012 after the multiple crises
of H2 2011; this is likely to put downward
and volatile pressure on commodity prices
until improved conditions prevail in H2 2012.
The oil and energy sectors should continue to
lead commodity sentiment,” the bank stated
in its latest report on the global commodities
outlook for 2012.
Standard Chartered expects the aluminium
price to average USD2,100/t in Q1 2012 and
USD2,300/t in Q4 2012, before it rebounds
to USD2,500/t in Q1 2013. According to this
bank, based in London, 2012 promises to
be another volatile year, particularly in the
first half as the crisis in Europe will continue.
The bank expects equity markets to have a
significantly better year than in 2011, after a
challenging start, and very strong gains in the
second half of the year as quantitative easing
gives results.
Danske bank in its latest research report
said the worrying signs from China persist, and
is still looking for a Chinese recovery in 2012.
“While we remain cautious in the short to
medium term and look for commodity prices
to remain under pressure, on the longer-term
horizon (6 to 12 months) we continue to see
good value in commodities,” the bank said.
It predicted that the aluminium price would
average USD2,100/t in Q1 and USD2,400/
t in H2, with an average over the year of
USD2,275/t.
What to expect in 2012?
The aluminium price outlook for 2012, especially for the first half, is very bleak and it
would not be a surprise to see the price stagnate around or even below the USD2,000/t
limit during the first two quarters. However,
there is no consensus among analysts regarding aluminium price performance in 2012, with
some leading institutions conflicting in their
forecasts, which range between USD1,8002,650/t. What is certain is that the European
debt crisis and tensions in the Persian Gulf
will not be resolved any time soon, and the
whole of 2012 may be affected if these two
developments change for the worse. It would
be a rather exhausting play: the Euro zone trying to overcome disintegration and, in parallel,
the global economy in the stranglehold of high
oil prices. Answers to both questions may be
given this year with the start of resolutions.
The third major question important for aluminium price performance this year relates to
the Chinese economy. Even though it is expected to ease slightly from last year, there
is no visible surprise on the horizon. Chinese
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23
production should satisfy demand this year
too, without significant exports or imports of
primary aluminium and aluminium products.
Imports may be higher in the first half of the
year and exports in the second half, making a
balance for the year. The global market will
remain in surplus, at around 1m tonnes, while
expected production cuts will be compensated
by new capacities entering production in India and the Middle East. The price is expected
to oscillate even more frequently than last
year but it should not wander far from the
USD2,000/t level in either direction. Only exceptional spikes of the oil price could push it
substantially higher temporarily, though for a
short period.
Author
Goran Djukanovic is an aluminium market analyst
and a consultant / advisor to the Montenegrin government on aluminium and energy markets. Email:
[email protected]. He is located in Podgorica, Montenegro.
TMS 2012 – wide range of technical symposia
topics will include (1) deformation / damage / fracture mechanisms in light metals and
alloys subjected to various loading conditions,
(2) deformation and damage / crack growth in
the presence of multiple damage mechanisms
such as corrosion, creep and fretting, (3) alloy development, structural characterisation,
mechanical properties, and in-situ characteriTMS 2012 will feature almost 4,000 technisations utilising state-of-the-art techniques,
cal presentations and 70 unique symposia.
(4) multi-scale modelling and multi-physics
The conference will focus on varied technical
approaches of deformation, damage and fracthemes: • Advanced Characterisation, Modelture.
ling and Materials Performance • High PerElectrode Technology for Aluminium
formance Materials • Light Metals: AluminProduction:
This seminar is a component of
ium, Magnesium and Titanium • Materials and
the
Light
Metals
Symposium and will focus
Society: Energy and Sustainable Production •
on
carbon
anode
raw materials and properMaterials Processing and Production • Nanosties,
paste
plant
design and operation,
cale and Amorphous Materials.
baking
furnace
design
and operation,
The Light Metals programme
rodding
room
design
and
operation,
brings together representatives from
anode
quality
and
performance,
soluthe world’s largest light metals comtions
for
carbon
plant
environmental
panies and research organisations to
issues and safety, cathode and cathode
discuss the latest developments in the
materials, cell preheating and start-up
field. Planned symposia include:
(as related to pot life); spent potlining,
Aluminium Alloys – Fabrication,
Characterisation and Applications:
inert electrode fabrication and materiThis symposium covers all aspects of
als science.
Magnesium Technology 2012:
the physical and mechanical metallurThis symposium is one of the largest
gy of aluminium alloys. It addresses
yearly gatherings of magnesium spefundamental and applied research as
cialists in the world. Papers are prewell as product development, testing
sented on all aspects of magnesium
and implementation of aluminium
technology, ranging from primary
foil, sheet, plate, extrusions, forgings
production to applications and recyand composites for end applications As in 2011, TMS 2012 will include a three-day exhibition, which will
cling as well as from basic research
including transportation, packaging bring together industry leaders buyers, engineers, scientists and researchers from all major countries
Photo: ALUMINIUM
to industrialisation.
and other key product segments.
TMS 2012 will include a three-day exhibiAlumina & Bauxite: This symposium, along Cast Shop for Aluminium Production: This
with Cast Shop Technology, Aluminium Re- symposium will cover the areas: charge mate- tion, which will bring together industry leadduction Technology and Electrode Technology rials, pre-furnace treatment, melting, fluxing, ers, buyers, engineers, scientists and researchcollectively form the Light Metals Symposium, filtration, cast processes, automation, process ers from all major countries. Companies will
where industry experts and academia from all modelling and control, environmental issues, showcase their products and services at the
over the world meet each other and share in- grain refinement, cast structure, and safety. exhibition, which will be held from 12 to 14
Papers on carry-over impact and prevention, March.
formation.
Aluminium Processing: Lectures will be metal loss, metal purity capture, sodium and
given on the areas of machine design, process other impurities, and equipment and logistics For more information on TMS 2012 registration and accommodations, and the schedule
control, production scheduling, measurement enhancement, will also be featured.
Deformation, Damage, and Fracture of of programming and events, visit www.tms.
technology, microstructure evolution and
characterisation, process modelling, material Light Metals and Alloys: The Symposium org/tms2012.
The Minerals, Metals & Materials Society’s (TMS) 141th Annual Meeting &
Exhibition will be taking place from 11 to
15 March 2012 in Florida. The meeting
will again feature a wide range of technical programming and events.
24
modelling, tribology, heat transfer, surface
generation, defect measurement and control.
Aluminium Reduction Technology: Papers
are invited on the following subject areas:
aluminium reduction technology, cell start-up
and early operation, cell modernisation and
productivity increase, process control, modelling of cell design, environmental aspects,
fundamentals, bath chemistry, power modulation, power supply improvements, inert anode
operation, emerging reduction processes, safety issues in reduction lines, aluminium trend
and market demand, energy saving initiatives
in reduction process, changes / initiatives in
reduction operation to cope with the financial
crisis.
Images: Dubal
Dubal proprietary technology licensed to Emal Phase II
Dubal Emal Technology Licensing Agreement signing ceremony on 22 December 2011. From left: Saeed Al
Mazrooei and Yusuf Bastaki of Emal; Ali H A M Al Zarouni and Abdulla Kalban of Dubal
The substantial sums of money and human intellect invested by Dubai Aluminium (Dubal) in research and development
over the past quarter century has rewarded the company through excellent growth
in aluminium production per pot at the
company’s Jebel Ali smelter, rising from
1.46 to 1.77 tonnes per day per pot between 2000 and 2011. This, together with
a series of sequential expansions to a hot
metal capacity of one million tonnes per
year, has transformed the entirely stateowned enterprise into the world largest
single-site pre-baked anodes aluminium
smelter in the world. In December 2011,
Dubal and Emal formalised the licensing
of Dubal’s proprietary high amperage
DX+ smelting technology at Emal Phase
II.
Ongoing investment in research and development has recently earned Dubal recognition
as a provider of advanced reduction cell technologies that rank among the best available in
the market. A case in point is Dubal’s proprietary DX technology, developed in 2005. It has
been installed in the 756 cells (in two potlines)
that constitute Phase I of Emirates Aluminium
(Emal) – the greenfield smelter development
at Al Taweelah, Abu Dhabi, which is owned
jointly by Dubal and Mubadala Development
Company (in equal shareholding). Operating
stably at 350 kA, the DX cells at Emal Phase
I were fully commissioned by the end of December 2010, giving the plant a nominal production capacity of 740,000 tpy in 2011. The
26
that both DX and DX+ technology were fully
in-house designed, modelled, tested and optimised. “The evolution of DX+ technology from
DX technology was also driven by an ongoing
quest to decrease the capital cost per tonne.
We spent months modelling and engineering
the designs, testing various parameters before
building five DX+ technology cells in the Eagle
pilot section of our plant. The DX+ cells were
energised between June and August 2010, and
have achieved the desired performance standards as per our modelled predictions from November 2010 onwards,” he says.
Mr Zarouni explains that the main physical
difference between the two technologies is the
size of the cell. “The DX+ cells are similar to
DX cells, but larger in size: the potshell is 0.3
m wider and 0.6 m longer. However, the potto-pot distance is unchanged at 6.3 m – i. e. the
same as in DX cells. The net result is that the
productivity per square metre of potroom is
increased by more than 17 percent,” he says.
The most significant difference is that the
amperage of the DX+ cells is higher than of the
DX cells. “DX+ cells were designed to operate
at 420 kA initially but are ultimately anticipated to operate at up to 460 kA. The busbar
configuration for the two technologies is the
same. However, the busbar cross-section in
DX+ cells is larger to accommodate the higher
amperage. While both cells have 36 anodes,
the size of the DX+ anode has been increased
to match the greater potshell dimensions and
to maintain the current density at higher amperage,” he says.
amperage of the cells has been increased to
353 kA over the course of the year. This, together with improved efficiencies, will result in
increased metal production levels to 750,000
tpy as well as yielding associated benefits in
terms of energy-efficiency and environmental
protection.
DX technology has also been installed in a
dedicated 40-cell line within the Dubal smelter. Operating stably at 380 kA, the line yielded
42,500 tonnes in 2010.
More recently, Dubal’s new generation
DX+ technology (developed in 2010) has been
specified for Emal Phase II, which will entail
the construction of a
KPI of DX+ Eagle demonstration cells (at 430 kA) and industrial design
third 444-cell potline
Average of 5 DX+ Emal Phase II
within the Emal comKey performance indicators (KPI)
DX+ cells
(Design criteria)
plex. Operating initially
Amperage (kA)
429.7
420 – 460
at 420 kA, the DX+
Current efficiency (%)
95.0
> 95.0
cells are expected to
Cell voltage (V)
4.18
< 4.25
yield an additional anSpecific energy* (kWh/kg Al)
13.11
< 13.33
nual production capacNet carbon consumption (kg C/kg Al)
0.405
< 0.415
ity of 520,000 tonnes
Aluminium purity (%)
99.93
> 99.89
(start-up is scheduled
for December 2013). A
* Based on 4.31 V actual minus 0.13 V for design changes (including larger busbar cross-section) in
the industrial version of DX+
simultaneous upgrade
to Emal’s DX cells, by
implementing improvements designed and As the key performance indicators confirm
tested by Dubal, will boost the production (see table), Dubal has successfully achieved
yield from Emal Phase I by 50,000 tonnes. its objectives through DX+ technology – speThis means that, by the end of 2014, Emal will cifically to improve productivity while reduchave an annual capacity of 1.3 million tonnes ing the operations’ impact on the environ– all of it produced using Dubal’s reduction ment through improved energy efficiency
and minimised emission levels. Al Zarouni
technologies.
Dubal’s Ali H A M Al Zarouni (vice presi- points out that, for expediency and timedent of Smelter Operations) proudly states saving, the DX busbars were retained in the
SPECIAL
Emal celebrates
million tonne milestone
DX+ cell in Dubal’s Eagle section
DX+ Eagle demonstration cells, with minor
variations to improve cell stability at higher
amperage. “This was a disadvantage, as the
cell-to-cell voltage would be higher than in an
industrial implementation. At industrial scale,
with the planned amperage increases, the performance of DX+ technology would be even
better,” he says.
N
Spouts and Stoppers
In November 2011, less than two years since
the commission of its Al Taweelah smelter in
December 2009, Emirates Aluminium heralded
the production of one million tonnes of aluminium. The average daily metal production
since 2009 has been 1,400 tonnes. Current
production stands at 2,035 tonnes of hot
metal per day.
Al Mazrooei said: “With Phase Two construction now underway and expected to
reach full production by 2014, Emal is well on
track to meet future increased global aluminium demand. It is also significant that we
have achieved this major landmark without
compromising our commitment to the health
and safety of our employees and our responsibility for the environment.” He referred to
safe working conditions, most notably with
no lost time injuries on its reduction potlines
in 2011; equivalent to five million man hours.
Ceramic Foam Filters
For Aluminium DC Casting
w w w.drache-gmbh.de
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[email protected]
27
Shaped cathode for the minimisation of the
Hall-Héroult process specific energy consumption
R. von Kaenel and J. Antille, KAN-NAK S.A.
More and more aluminium smelters are
testing new shapes of cathode to reduce
their specific energy consumption. This
paper compares the cathode voltage drop,
the cell magneto-hydrodynamic stability,
and the total specific energy consumption for four potential cathode designs.
The lowest cathode voltage drop is not a
necessary condition to realise the lowest
specific energy consumption.
It is well known that the biggest potential for
decreasing the specific energy consumption
Case 0: Reference cathode
Case 1: Electrical insulation
around collector bar?
Case 2: Step in the cathode?
Case 4: Groves on cathode surface and insulated
collector bars (40 cm)
Fig. 1: Five cathode designs for the same cell technology
28
Images: KAN-NAK
Case 3: Blocks on
cathode surface
of electrolysis cells still lies in reducing the
anode to cathode distance (ACD). Unfortunately, lowering the ACD leads sooner or later
to detrimental magneto-hydrodynamic instabilities as waves provoke short-circuits and so
harm the current efficiency and specific energy
consumption.
There are at least two ways of modifying
the cathode to help decrease waves, and so the
ACD. The first method consists in improving
the magneto-hydrodynamic cell stability by
changing the current distribution in the liquid metal, while still keeping a standard flat
cathode surface. The interaction of the current
density with the magnetic field in the liquid
aluminium determines the critical ACD. This
critical ACD can be lowered by modifying the
cathode dimensions, as well as its properties,
its collector bar design and / or the busbars.
The second method consists of changing the
shape of the cathode surface. Indeed, liquid
metal waves that are generated by the magneto-hydrodynamic cell state can be damped by
using uneven cathode surfaces. This has some
similarities with how water waves are damped
by turbulence when reaching shallow water.
This paper analyses the potential advantages that can be expected from using these two
techniques. The analysis needs the determination of the full thermal, electrical and magneto-hydrodynamic cell state in the presence of
liquid aluminium waves in the cell. The analysis was performed with a specialised software
that was presented earlier [1-4]. Many designs
of shaped cathode can be considered, and we
will restrict this study to geometries that have
been published earlier [5-7]. In order to decrease the ACD while maintaining thermal
balance, between heat input and heat losses,
it is necessary to change other parameters. Increasing the current is the most common way
to go, but one can also consider decreasing
the metal level and / or improving the thermal
insulation. Both methods achieve improved
specific energy consumption in given ranges
but they may lead to quite different electric
power needs for the plant.
Every cell technology is different. Technologies differ in their overall geometry, in their
anode current density, in their busbar system,
in their bath chemistry, and so on. We must
therefore analyse each specific case to identify its potential for improvement. However,
in order to get a quantified feeling of the impact of changing the cathode, we have considered a ‘typical’ side-by side-cell design operated at 350 kA with an anode current density
of 0.9 A/cm2.
Cathode design
The change of cathode design affects the current density in liquid aluminium, the magnetic
field, the velocity field, the ledge shape, the
thermal heat losses, and many other parameters, so as to finally define a new cell state
for any given current. It also defines the lowest
achievable ACD for a given current in the line.
Fig. 1 shows the five different cathode designs
that were considered for the discussion.
There are many parameters that must be
checked to achieve a good cell technology. As
it would be too tedious to present the full interaction of all these parameters, we will present
the impact of cathode change on a few parameters, namely:
• the surface current density on the cathode
• the electrical potential inside the liquid
metal
• the cathode voltage drop (CVD)
• the damping factor for the metallic waves
• the specific energy consumptions.
In this analysis the current is increased until the cell reaches instability at the limit of
magneto-hydrodynamic stability. While the
current is being increased, the ACD must be
decreased to keep a constant internal heat production. All calculations are performed on a
full three-dimensional model considering the
neighbouring potline cells.
Results
Fig. 2 shows the shape of the electrical potential
in the liquid metal, the current density at the
liquid metal – cathode interface, and the cathode voltage drop. The current density is calculated in the upper part of the cathode, close
to the interface. It represents the local current
density that the cathode blocks must tolerate
over time. A high current density causes a high
rate of electro-erosion, and it should be avoided as it may compromise the cell life. In the liquid metal, the current is flowing perpendicular
to the lines of equal electrical potential. Large
and horizontal current densities represent a
SPECIAL
improves the situation drastically. However, a
current density of 1.43 A/cm2 remains at the
corner of the step. Only the magneto-hydrodynamic calculations can tell which situation is
best. The CVD is a little lower when compared
to the reference case.
Fig. 5 shows the results for the blocks on the
cathode surface. The current density is very
high because the current flows around the carbon blocks (liquid metal is a better electrical
conductor than carbon). The CVD is slightly
lower (the mean cathode thickness has been
decreased by the height of the carbon blocks).
The collector bars should be insulated over a
suitable length to avoid the horizontal current
in the liquid metal.
Fig. 6 shows the results for Case 4 (groves
on cathode surface, and insulated collector
bars). The maximum current density is decreased from 2.5 A/cm2 to 1.6 A/cm2 which is
equivalent to the reference case. The CVD is
increased to 377 mV, but the current is flowing
vertically. The solution looks interesting.
The most important data are summarised
in Table 1, which shows the potential of each
solution for higher production, assuming that
the current can be increased. The current
DUBAL
potential destabilising
factor for the cell magneto-hydrodynamic
state. It is very clear
that in this reference
cell, too much current
is moving horizontally
in the liquid metal,
leading to a high current density about 1.5
A/cm2 close to the
edge of the cathode.
The first idea for
Fig. 2: Electrical potential lines, current density and CVD for
improving the current the reference cathode blocks (Case 0)
distribution is to insulate the outer end of collector bars as shown in the maximum current density to 1.09 A/cm2,
Fig. 3 (next page). The resulting change of cur- but the flow directions now almost vertical in
rent density is quite impressive and it depends the liquid metal. This will give an important
largely on the length of insulation. The maxi- potential to decrease the ACD before reachmum current density is just above 1 A/cm2 ing the cell magneto-hydrodynamic instability.
when the length of electrical insulation is 40 This is a must for compensating the increased
cm around the collector bars. This first modi- CVD to 383 mV.
Fig. 4 shows the results for the step cathfication helps to reduce the maximum current
density by 22%, and it demonstrates the ad- ode. The step does not help very much for the
vantage of keeping the CVD at 261 mV. The current distribution in the liquid metal. It is
longer insulation helps drastically to even out still flowing mostly horizontally. Insulating the
the current density. Not only has it reduced collector bars combined with the step cathode
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Fig. 5: Electrical potential lines, current density and CVD for blocks
on the cathode surface (Case 3)
Fig. 3: Electrical potential lines, current density and CVD
when insulating part of collector bars (Case 1)
Fig. 6: Electrical potential lines, current density and CVD for
groves on cathode surface and with insulated collector bars (Case 4)
was increased until the cell stability damping factor was roughly the
same for each case, this is to say, equivalent to the reference case.
Increasing the current through improved cell magneto-hydrodynamic
stability is the most efficient way for decreasing the cell specific energy consumption. As the cell operates at the same level of stability,
the current efficiency was assumed to be unchanged.
Conclusions
Fig. 4: Electrical potential lines, current density and CVD
for the step cathode (Case 2)
30
Four different cathode design changes were studied for a given cell
reference design. The cathode plays a fundamental role in the cell’s
magneto-hydrodynamic state and it can trigger drastic changes in the
specific energy consumption. The lowest CVD does not reflect the
lowest specific energy consumption. A shaped cathode in terms of
steps, blocks or groves may help considerably to stabilise the metal
pad, however, the current distribution also requires correct design
in order to achieve the benefit. Horizontal current density in the
liquid metal is one of the most sensitive parameters to consider in
the design. The use of sharp changes at the surface of the cathode
automatically leads to local high current densities that may be detrimental for the cell life. In this study, no consideration was given to
the cell life and operation conditions.
Any of the four analysed solution need to be tuned to the spe-
SPECIAL
Case
Modifications
0
1
Reference
2
3
4
Collector bars insulation
Step cathode
Blocks on the surface
Groves in the cathode
Col. Bars
Insulation (cm)
Current
(kA)
0.00
0.15
0.40
0.00
0.40
0.00
0.40
345
355
370
365
390
370
400
MHD
Specific Production
CVD Internal
damping
energy
increase
(mV) heat (kW)
factor (1/s)
(kWh/kg)
(%)
-0.005
-0.005
-0.006
-0.005
-0.006
-0.005
-0.006
262
261
383
259
334
254
377
681
681
688
687
681
688
676
13.33
13.17
13.02
13.08
12.70
13.02
12.55
3%
7%
6%
13%
7%
16%
Table 1: Specific energy consumption as function of cathode design
cific cell technology in order to achieve a
good magneto-hydrodynamic state. There are
many more possibilities to change the cathode
surface, and the authors believe that there is still a large
potential for improving cell
efficiency and productivity.
kA aluminium reduction cells with a new type of
cathode design, Light Metals 2010, ed. J. A. Johnson
(TMS, Warrendale, Pa), pp. 485-488
References
René von Kaenel received his diploma of physicist
from The Swiss Federal Institute of Technology
Lausanne (EPFL) with a specialisation in plasma
physics before working for ICL in London and
specializing in computer science. In 1981 he joined
Alusuisse and became head of the modelling activities for smelting technology. In 2000, he received
the title of Electrolysis director in the new Alcan organisation and further supervised Alcan’s modelling
activities. Since 1981 he has participated in many
smelter modernisation projects all over the world,
leading to large productivity increases. He has published many articles on electrolysis cells, casting
processes and inert anode technology. In 2004 he
created KAN-NAK S.A., a specialised company for
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[1] J. Descloux, M. Flück and
M.V. Romerio, Modelling for instabilities in Hall-Héroult cells:
mathematical and numerical aspects. Magneto-hydrodynamics
in process metallurgy, Light Metals 1992, ed. E.R.Cutshall (TMS,
Warrendale, Pa), pp. 1195-1198
[2] J. Descloux, Y. Jaccard and
M.V. Romerio, Stability in aluminium reduction cells: a spectral problem solved by an iterative procedure, Light Metals
1994, ed. U. Mannweiler (TMS,
Warrendale, Pa), pp. 275-281,
[3] R. von Kaenel and J. P. Antille, On the stability of alumina
reduction cells, 5th Australasian
Aluminium Smelter Conference,
1995, Sydney, Australia, ed. B.
Welch and M. Skyllas-Kazacos,
pp. 530-544
[4] J. Descloux, M.Flück and M.
V. Romerio, Modelling of the stability of aluminium electrolysis
cell, Non-linear partial differential equations and their applications, Collège de France, Seminaire Volume XIII, Ed Longman
1998, pp. 117-133
[5] R. von Kaenel and J. P. Antille, Modelling of energy saving
by using cathode design and inserts, Light Metals 2011, ed. S J.
Lindsay (TMS, Warrendale, Pa),
pp. 569-574
[6] J. Li and X.-J. Lu, Industrial
test of low-voltage energy saving
aluminium reduction cell, Light
Metals 2010, ed. J. A. Johnson
(TMS, Warrendale, Pa), pp. 399404
[7] Z. Wang and M. Feng,
Study of surface oscillation of liquid aluminium in 168
Authors
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31
the optimisation of processes, in particular the HallHéroult process.
Dr. Jacques Antille obtained a degree in Physics at
the University of Lausanne in 1978 and his PhD at
the European Centre of Nuclear Research (CERN)
in 1984. Soon after he joined the Alusuisse Technology and Management Ltd and worked on modelling projects of the Hall-Héroult process and cast-
ing processes. In 2004 he joined KAN-NAK S.A.
where he is leading magneto-hydrodynamic studies
for the optimisation of the electrolysis process as
well as all measurement techniques.
Precision pot feeding for better environmental protection
P. Eggestig, Bosch Rexroth
In 2000 Rexroth had already come into contact with a project from Kubal in Sundsvall,
Sweden, as a part of which environmental
protection was to be assured according to the
new EU emission limits. The primary goal focussed on reducing fluoride gas emissions by
70 percent. Kubal is Sweden’s only aluminium
plant, owned by UC Rusal. A while ago, Rusal
had considered discontinuing its production
in Sundsvall. However, thanks to a large-scale
conversion and a new manufacturing process
in which Rexroth’s new solution for process
control plays a key role, Kubal in Sundsvall
will be able to operate highly cost-effectively
in the near future. The new technology is implemented in all of Kubal’s 262 electrolysis
pots in Plant 2 in Sundsvall. The goal for reducing fluoride gas emissions by 70 percent
has been achieved. Moreover, metal production will also increase by 40 percent after the
conversion: 1.1 tonnes of aluminium will be
extracted from each furnace daily.
Images: Bosch Rexroth
Fluoride gas emissions were reduced by
70 percent in aluminium production with
pneumatic crust breakers. Rexroth has
developed a product with the potential
to revolutionise aluminium smelting.
A newly developed process for adding
alumina enables a more comprehensive
process control, lower maintenance costs,
improved aluminium quality and reduced
emissions for across-the-board environmental protection.
Kubal’s capacity is about 130,000 tpy of aluminium which corresponds to roughly half of the aluminium
consumption in Sweden
The double-acting cylinders have a diameter of
160 mm and a length of 600 mm. Chisels bore
two holes into the crust, enabling aluminium
oxide and fluoride to be injected into the molten cryolite at two places. The more uniformly
and evenly the two materials are added, the
more primary aluminium can be produced.
This also significantly reduces polluting emissions. If the chisel does not penetrate the
crust during the first attempt, the pneumatic
pressure is tripled to six bar during the next
attempt. If this also fails, the control system
New process with dosed supply
In order to achieve the dramatic reduction in
fluoride gas emissions, Kubal discontinued
its former alumina addition process, which
involved the bulk transfer of hundreds of
kilograms of aluminium oxide with one large
‘delivery’ to the furnaces. Now a dosed supply
technique is used; smaller doses of one to two
kilograms are supplied approximately once
every minute.
During this process, two pneumatic crustbreaker cylinders penetrate an approx. 10
cm-thick oxide crust above the molten metal.
32
Melting furnaces in Kubal’s Plant 2 casthouse in Sundsvall. The goal for reducing fluoride gas emissions by
70 percent has been achieved.
SPECIAL
operator. The crust-breaker cylinders operate
approximately every minute, 24 hours a day,
all year round.
When the shaft on the crust breaker cylinders penetrates the crust, it should not enter more than the necessary minimum depth
into the melt. With excessive penetration, an
undesired quantity of iron dissolves into the
cryolite, contaminating the aluminium. Also
the chisel suffers increased wear and must be
replaced, leading to higher costs.
System optimisation
Covering the melt is an approx. 10 cm-thick crust
of solid cryolite and alumina that the pneumatic
piston must break before every feeding. The crust
breaker chisel penetrates the scrust and maintains
the opening. Alumina and aluminium fluoride can
then be fed through this aperture.
switches to high-energy impact function. The
chisel then chops up the surface crust. If that
also does not work, an alarm signal is sent to an
Rexroth has developed a system in which the
chisel that penetrates the melt has as little
contact with the melt as possible. This system,
named ‘System Optimiser’, is patented [1].
Each of the 262 electrolysis cells operates in
series with 160 kA and about 4 V per pot to
convert alumina to aluminium. Thus, an electric potential is present in the pot, which instruments register when the chisel penetrates the
crust and comes into contact with the melt. The
System Optimiser receives a voltage signal as
the shaft touches the melt and signals to the
Kubal control system that an opening has been
created in the crust. The Kubal control then
introduces alumina and aluminium fluoride
into the melt in the correct quantities.
The traditional solution to date was that the
piston was extended until it reached its end
position in order to ensure that the opening
produced in the crust remained open. This long
stroke resulted in a number of disadvantages:
About Kubal
Kubal is the largest metal processing operation in the Swedish Province of Västernorrland, and is Sweden’s sole smelter of primary
aluminium. Of the aluminium manufactured
in Sundsvall, approx. 50% goes to customers
in Sweden and 50% is shipped to buyers in
the rest of Europe to make a large number of
different products – from aluminium foil and
packaging of all kinds, to construction material and vehicle components. The smelter’s capacity was increased from an initial 2,000 tpy
to about 130,000 tpy today. That corresponds
to roughly half of the aluminium consumption in Sweden.
Thermo-Calc
Software
Thermodynamic and Diffusion Simulation Software
for Aluminium alloys
Thermo-Calc:
9 Predictions of stable and metastable phases for
multicomponent alloys
9 New database TCAL1 with 26 elements
9 6FKHLOVROLGL¿FDWLRQVLPXODWLRQV
DICTRA:
9 Diffusion controlled phase transformation simulation
9 Microsegregation kinetics during casting
9 Homogenization treatment and aging
TC-PRISMA:
9 Modelling of nucleation, growth and coarsening
9 Time-Temperature-Precipitation (TTP) diagram
9 Size distribution, number density and mean radius
Thermo-Calc Software AB
Email: [email protected]
Phone: +46-8-545 959 30
Fax: +46-8-673 37 18
www.thermocalc.com
For a listing of local agents and
DI¿OLDWHVLQ\RXUUHJLRQSOHDVH
visit our website and look under
Contact.
unnecessary wear to the chisel and piston, an
unwanted introduction of iron contamination
and, first and foremost, Kubal did not obtain
complete control over the electrolysis process.
Although the piston reached ist end position, it
did not always penetrate the crust, but sometimes only been pressed the crust further into
the melt. In this case it created no opening,
and the electrolysis process continued on this
faulty basis. The additives could not dissolve
in the bath, causing the pot to ‘run on empty’.
This lack of alumina causes an anode effect
with excess voltage and fluoride gas emissions.
However, the worst-case scenario involved the
delayed supply of too much alumina into the
pot within a short time. Too much alumina
cannot all dissolve, and results in deposits
as sludge. This overfeeding effect causes an
increase in resistance, voltage and temperature, seriously reducing the pot’s service life.
By avoiding overfeeding, the system reduces
gas emissions – primarily fluoride gas – by 70
percent. The new technology has achieved
considerable gains in efficiency as well as exceedingly positive cost synergies.
but also left the best impression, gaining points
with technical support and fast response times
so as to secure this large contract.
Reference
[1] C. Tour, Crust-breaking device operating system
for metal melts has inductive position sensor to report impact of chisel, DE patent 10 2008 010 175
(application date 20 February 2008)
Success factors
Rexroth was able to offer the most technically
advanced process. As a matter of course, other
factors also play a role in such a transaction.
Rexroth did not only have the best technology,
Author
Peter Eggestig is Bosch-Rexroth’s sales manager
pneumatic in Sweden. He has directed the Rexroth
project with its sale at Kubal since 2000.
Trends in modern rectifiers – energy efficiency and availability
Specific power losses can be reduced using higher voltages which correspond to
a higher number of pots in series, beyond
360 pots in one potline. Today’s trend
is to still higher production capacities at
optimum investment costs and higher
efficiency. This requires a rectifier with
higher DC voltages up to 2,000 VDC.
The rectifier system being one of the
key elements in aluminium smelters,
this makes the availability (reliability) of
power supply most essential for economical performance. Aside from new plants,
revamping old potlines requires increased
DC voltage.
This paper briefly discusses efficiency
aspects of new plants as well as the economic aspects of revamping old potlines
and the corresponding requirements of
rectifier systems. It also describes power
availability aspects related to designing
a higher voltage rectifier system, as well
as areas related to network performance.
The way to meet these requirements involves using a systemic approach to find
special solutions.
Efficiency improvements – in other
words, lower losses per million tonnes
smelted – are achieved by operating rectifiers at higher voltages to serve a larger
number of pots in series. Improvements
in pot technology reduced individual pot
voltage from 4.3 V to almost 3.85 V, thereby
significantly improving process efficiency.
The paper presents results based on design calculations for rectifier systems up
to 2,000 VDC. A reliable and flexible
34
Images: ABB
S. Tambe, ABB Switzerland
Fig. 1
control system with a state-of-the-art optical DC metering system is also an integral part of the DC power supply. A modern DC metering system not only meets
primary requirements, but it also has
lower auxiliary power consumption. This
also contributes to improved efficiency.
Rectifier systems are a vital power element
in the aluminium smelting process. Continuous availability of DC supply is a major factor
affecting the economic performance of these
plants. Unscheduled shutdowns result in huge
financial losses. While efficiency is important,
an availability is vital to avoid unplanned shutdowns. Modern technologies are designed to
avoid such situations even when potlines employ local generation, sometimes operating in
islanded mode.
Initial investment costs are high for alu-
minium potlines. These costs have two components: fixed cost and variable cost proportional
to number of pots and parts. On an average 33
percent of smelter production cost is electrical energy. Due to increasing energy tariffs
around the world, aluminium production is
viable only when conversion and electrical efficiencies are high, thus reducing some of the
major variable costs.
Today, potlines can have more than 400
pots. More pots demand special logistics considering the requirements of metal tapping,
anode replacement, maintenance work, such
as beam raising, bath crushing, covering.
A higher number of pots means higher DC
voltage. The electrical insulation for the pot
tending assembly cranes and workers does
not appear to be a constraint. Electrical shock
hazard does not appear to be a problem either.
However, one must follow local safety regula-
SPECIAL
tions and take the necessary procedures into ment. Optimising losses in rectifier systems is
account. The risk of open circuits is not higher. not easy due to physical constraints.
As shown in Fig. 1 [1], some losses are
The major challenge is the ability of rectifiers
to supply higher DC voltage. Because the re- constant for a given potline current and some
quired cross section of the busbars depends vary with current. This leads to the important
on current, we can keep the same number of conclusion that for a given potline current in
rectifier units, DC isolators, DC measuring a potline with a large number of pots, constant
system and the buffer voltage to handle an- losses become relatively smaller as a percentode effect (with modern anode effect handling age of output or, in other words, losses are
technique). This allows a lower initial invest- smaller per million tonnes output of aluminment per million tonnes smelted with a higher ium.
number of pots. In short, economies of scale
Power losses, maintenance costs and manrequire a higher number of pots, and hence power requirements for plant operations are
technology needs to be adapted for higher lower and so economically more viable when
voltages.
There is a new trend in
revamping old potlines. The
number of rectifier units is
reduced by connecting two
or more potlines in series.
Such revamping is carried out
while the plant is in operation.
Therefore it requires a high
level of expertise.
Smelters are moving to increased pot amperage and to
longer potrooms with higher
DC voltages in order to make
capital savings on rectifiers,
transformer bays and switchgear as well as some savings
on the operational losses. Also,
this simplifies the maintenance cost of the rectifier and
its auxiliary equipment. Maintenance cost savings are reflected in reduced manpower
requirements. If two potlines
are connected in series, the
electrical maintenance cost
INNOVATION LEADS TO
can be reduced by 40 percent.
Manufacturing
rectifiers
for higher voltages presents
various challenges. The soluUSE THE ORIGINAL
tions to these challenges lie in
BCT PASTE KNEADER – FOR MORE
designing a reliable and safe
rectifier system.
Productivity
Solution for
higher efficiency
Rectifiers, busbars and transformers are major sub-systems
that are important sources of
energy losses, although there
are other auxiliaries and measuring systems that also contribute to losses. Transformer losses are easy to optimise because
it is a question of initial invest-
potlines have more pots, that is, when they
operate at higher voltages. Therefore, if power
is available, it is more economical to plan a
longer potline in advance than to build several shorter potlines. When power losses are
calculated from voltage measurements, then
transformer losses are not taken into account.
Fig. 2 shows rectifier losses per MW output
for 105 kA units, up 2,000 VDC.
Overall efficiency improvement [1]
The above discussion on losses relates to the
rectifier system only. However, the transform-
A NEW GENERATION
Efficiency
Reliability
Get 100% paste – with max energy input – save 25% energy
Get 100% performance – with optimised process zone – save 10% space
Get 100% the original – with BCT spare and wear parts – save costs
In its 6th generation the BCT Paste Kneader is a fully revised unit with new gearbox,
new bearing system, embedded auxiliaries and more.
Y O U R PA R T N E R F O R T E C H N O L O G I E S
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Fig. 2
er is also a major part of the system, and so
its overall efficiency is of prime importance.
A case study showing improvement in overall
efficiency is provided below. This study compares the losses for two options, firstly for
1,300 VDC and a capacity of 245,000 tpy of
aluminium, and secondly for 1,380 VDC and
a capacity of 260,000 tpy of aluminium. This
comparison is based on actual measurements.
In the first case, rectifier and transformer
losses are 4,885 kW with five rectifiers in operation, whereas in the second case, losses are
expected to be 5,065 kW with all five rectifiers
in operation. In both cases, the potline current
is 320 kA.
Calculating further, we find that losses per
million tonnes equivalent amount to 19,939
kW in the first case and to 19,481 kW in the
second case. Thus an increase of about 6.2
percent in potline voltage leads to a reduction
of losses by 2.3 percent. So the potline with
higher voltage is preferable.
We extend the above results further to
compare a potline designed for 1,650 VDC
(27% increase from 1,300 VDC) and a capac-
ity of 340,000 tpy of aluminium. In this case
losses per million tonnes also decrease significantly to 14,239 kW (29% reduction) with five
rectifier units in operation.
But when the potline voltage increases to
2,000 VDC, the losses do not decrease linearly.
This is because the increase in diode semiconductor voltage rating caused additional losses.
Fig. 3 shows voltage versus losses for a given
potline current.
Efficiency improvements
and life enhancement
Potlines built up to the end of 1980s used
to have fewer pots due to technical limitations in many areas, including the rectifier
systems. The typical potline voltage used to
be up to 800 VDC. At the beginning of the
1990s the voltage could be increased beyond
1,000 VDC.
In the old potlines, which are more than
28 years in operation, major electrical components would have reached the end of their
life cycle [2]. Therefore many plants need to
replace DC power supplies. As the duration
of the plant and process life still exceeds 30
years, it was natural to replace electrical equipment, including rectifier systems [3].
Availability today of higher voltage rectifiers up to 2,000 VDC has made it possible to
unite two old potlines by connecting them in
series, and to replace a large number of old
rectifiers with less than half the number of new
rectifiers. This not only increases efficiency,
but it also significantly reduces operational
costs [4].
Some results published to one of the reequipped smelters show savings due to connecting potlines in series.
Before connecting in series:
• Potlines 1&2: losses of 12 rectifier / transformer units (2 potlines) approx. 6,500 kW
• Potline 3&4: losses of 16+1 rectifier / transformer units (2 potlines) approx. 9,000 kW
• Total losses approx. 15,500 kW.
After connecting in series:
• New substation after connecting each pair
of potlines in series will have together
7,000 kW; reduction of 8,500 kW
• Assuming the cost per kWh of 3 US cents;
cost savings of USD2.2m per year.
ABB carried out one more case study to prove
the saving in energy by connecting two 190
kA, 720 VDC potlines in series (see Fig. 4),
and the results were very encouraging.
Before connecting in series:
• Estimated losses for 2 potlines with existing
transformers and rectifiers are 5,710 MW*
• Step down transformer + regulating
transformer + 6 rectifier transformers
+ rectifiers: 2855.1 kW
• Output = 190 x 727 = 138.13 MW
• Efficiency = Output / (Output + Losses)
= 97.97% (actual* will be less)
• * The above losses do not include saturable
reactor losses, harmonics and auxiliary losses.
After connecting in series:
• New rectifier system rated at 5 x 55 kA,
1,650 VDC units
• Potline operating at 190 kA and
1,454 VDC
• Estimated losses of two potlines in series
are 3.139 MW*
• Expected savings in losses are 2.571 MW
• * The above losses do not include saturable
reactor losses, harmonics and auxiliary losses.
Availability considerations
for high voltage rectifiers
Fig. 3
36
Fig. 5 shows a rectifier designed for 103 kA,
1,650 VDC, ABB frame type construction:
Design methods and systemic approach: A
reliable rectifier system can only be ensured
SPECIAL
Over-voltage protection
This circuit is adapted for the selected topology, the selected semiconductor, the transformer parameters, the network parameters
and according to the operation for the process. The critical components that form the
overvoltage protection circuit are metal oxide
surge suppressors, capacitors and electrolytic
capacitors.
Plant layout and busbar engineering
Plant layout and busbar engineering play a
crucial role in the initial investment and efficiency. Excessive unsupported lengths should
be avoided, so keeping the safe distances to
withstand short-circuit forces.
Busbar layout also plays an important role
in electro-mechanical forces, and so affects the
design of support structures. Optimum busbar
cross section determines losses and so ultimately efficiency. Heat from the busbar system must be evacuated to atmosphere without
the need for an additional cooling system.
Fig. 4: Loss calculations at 190 kA and 720 VDC
if critical areas are designed with a systemic
approach. The adapted topology, sizing, redundancy, etc. is based on various plant system parameters. Some of these are:
• Whether the plant draws all its power
from the grid, or whether it generates
most of its power locally
• How much import / export of power can
occur before getting into islanding mode
• How much system redundancy is based on
process parameters.
The selection of topology and components has
to consider electrical network parameters as
well as process requirements [1]. Some critical areas are:
• Mechanical contact stability
• Ability to withstand electro-mechanical
forces in abnormal conditions to avoid
capital damage
• Tests for coordination of components such
as semiconductors, fuses, etc. and checks
for selectivity with simulations for
network parameters
• Rugged over-voltage protection and
protection philosophy.
All insulating materials used to isolate higher
potentials are non absorbent for water. Air
strike distances are adequate for the DC voltage level. To avoid flash-over between phases,
insulating plates separate the AC phases.
Welded ‘frame construction’ provides rigidity to the structure so as to withstand very
high electro-mechanical forces. Double commutation paths reduce current by half and
hence reduce forces. This also improves cur-
rent distribution in the semiconductors.
Nickel-plated aluminium surfaces give the
contact surface, which ensures many years
of mechanical and electrical contact stability.
Constant clamping pressure maintains good
contact and elimination of contact corrosion
between heat-sinks and semiconductors, resulting in constant heat transfer efficiency for
years of operation.
A closed loop ‘de-ionised’ water-cooling
system provides efficient and clean cooling.
Ionic corrosion, which is very chronic at higher
voltages, is practically eliminated by using the
right materials for the cooling circuit. Appropriate lengths of de-ionised water pipes are
selected based on higher rectifier voltages.
Control system
The AC 800 PEC (Power Electronic Controller): The control system function includes
closed loop current control, alarms, trips,
protections, various controls, metering, communication, trends, etc. This requires a highly
reliable and flexible system.
Fault tolerant challenge
In the case of old thyristor plants, a major problem is tripping during under-voltages, ground
Clear separation of
power and control wiring
There is an interface between power circuit
and control system. Fuse monitoring, temperature monitoring, etc. are located on the power
circuit but are monitored in the control system.
Isolation between these two systems is very
critical.
Various monitoring functionalities such as
busbar temperature, fuse monitoring micro
switches, etc. are part of rectifier system. These
signals are wired to control system input devices, while the connection of the over-voltage
protection circuit is wired to the power circuit.
All of this wiring is clearly separated and isolated. Wires have minimum sag to minimise
the effects of vibration.
Fig. 5: 103 kA, 1,650 VDC rectifier
37
faults and unexpected, very brief unbalance
between phases. Old analogue circuits could
not maintain the proper pulse positioning under such
conditions. This could result
i n
thyristor
sensing fibre looped around the current-carrying busbars. A single loop is commonly sufficient for high DC currents. The field (proportional to DC Current) dependent phase shift
(Fig. 7) between two light waves is a direct and
accurate measure of the DC Current.
Auxiliary power requirement
for
scale production of primary aluminium requires rectifier systems for potline voltages
up to 2,000 VDC.
References
[1] S. Tambe, C. Winter and S. Dhareshwar, ‘Rectifiers for Higher Voltages in Aluminium Smelters –
Challenges and Solutions’, Metal Bulletin, 2007,
Mumbai, India.
[2] S. Tambe and J. Frisch, ‘Upgrading rectifier systems – How to improve efficiency, increase reliability and reduce down time’, in PCIC IEEE, 2004
failures
and a plant outage.
The only alternative to avoid
unscheduled outages is the revamping or
replacement of the control system [5].
The AC 800 PEC control system is able to
maintain correct firing at up to 60 percent of
nominal voltage, and it provides ride through
functionality even if a phase is lost. The controller has built-in filters that clean synchronising voltages, avoid noise amplification, and
for certain durations can also block pulses
without tripping. This greatly increases the
availability and increases the safety of the
process.
Fibre-Optic Current Sensor (FOCS)
The ABB FOCS is a family of highly accurate fibre-optic current sensors developed for
measuring high DC currents. This technical
innovation is characterised by its easy and
flexible use. Based on the magneto-optic effect (Faraday effect) in a single-ended optical
fibre around the current conductor, the FOCS
can measure uni- or bi-directional DC currents
up to 500 kA with an accuracy of 0.1% of
the measured value. The main benefits can be
described as:
• Fast and easy assembly and installation
• Simple to transport
• Special building structure to house sensor
is not needed
• Immune to electromagnetic interferences
(magnetic centring, magnetic overload, etc.)
• Low power consumption
• No shunts.
The sensors also recover AC current components up to 4 kHz.
The signal is independent of the particular busbar arrangement, and it is insensitive
to magnetic stray fields from neighbouring
busbars.
Two light waves with orthogonal linear polarisations travel from the sensor electronics,
which include a semiconductor light source,
via a sensor fibre cable to the single-ended
38
Fig. 6: AC
800 PEC controller
FOCS requires only about 30 W constant
against about 20 W / kA measured by conventional measuring system. Energy requirements for 300 kA FOCS would be 262 kWh,
as against 52,560 kWh per year for a conventional system.
Conclusion
Energy efficiency and availability are keys
for successful operation of aluminium plant.
A single potline with a higher number of pots
is energy efficient and cost effective. The best
way to achieve higher efficiency for old potlines, operating under 800 VDC, is to connect
two potlines in series. Today, the competitive
[3] E. Knall, ‘ABB retrofitting concept for Rectifier
Plants’, ABB Industrie AG.
[4] S. Tambe and S. Dhareshwar, ‘Limits of Conventional Maintenance and Needs of Upgrading /
Revamping for High Power Rectifier Systems’, National workshop on power electronics, June 2005,
India
[5] S. Tambe, ‘Upgrading Control System with AC
800 PEC for Rectifier Systems’, Light Metals 2006,
ed. T. J. Galloway TMS, Warrendale, Pa), pp. 265270
Author
Shripad Tambe, Master of Technology, IIT Kanpur,
started in 1977 with HBB (Hindustan Brown Boveri),
India. In HBB India he was a senior research and
development manager. Up to 1999 Shripad Tambe
worked in various technical departments including
system engineering, ABB Switzerland. He is the inventor of two patents registered in many countries
in the area of rectifiers for DC arc furnaces. From
October 1999 to 2005, he was responsible worldwide for retrofit, revamp and upgrades of rectifier
plants for electrolysis and arc furnaces. Contact:
[email protected]
Fig. 7: DC FOCS and measuring principle
SPECIAL
Innovative energy and fluoride recovery
B. Herrlander, Alstom Power
In April 2011, the world’s largest singlesite greenfield aluminium smelter complex held an official grand opening of
phase one (Fig. 1, next page). The Emal
smelter complex is being built in two
phases. Phase one includes two potlines
with a total of 756 pots at 350 kA to
produce 750,000 tpy of aluminium. The
first pot was started 2 December 2009,
and in January 2011 the two potlines hit
full production. At the end of 2012, the
phase one capacity will be increased to
800,000 tpy of aluminium through a technology upgrade to 380 kA. Phase two of
the smelter began in September 2011 and
has one potline with 444 pots at 420 kA.
When phase two is finished in December
2014, the smelter will be the largest in the
world with a capacity of 1.3m tpy. Alstom
is selected supplier of Gas Treatment
The fluoride loop
Centres (GTC), Fume Treatment Centres
(FTC) and the pot feed system for phase
1, and of GTC and FTC for phase 2.
Only 15 years ago a new smelter of 200,000
tpy was considered normal. Today smelters
of more than 800,000 tpy of capacity are being built. Over the same period typical new
pot amperage has increased from 180 to 350
kA, and will go higher as demonstrated in the
Emal phase two. In an existing smelter amperage increase creep is one of the more cost
efficient ways to increase the specific production. However, the concentration of HF in the
off-gas from pots has risen correspondingly
from typically 150 to 180 mg/Nm3 to 350 to
400 mg/Nm3. At the same time, the limits for
allowable fluoride emissions from GTC and
FTC stacks have been reduced from approx.
2.5 to 0.7 mg/Nm3.
Alstom pioneered the dry recovery of fluorides
from pot off gases by adsorption on alumina
deploying a fabric filter. Over the years the
developments have resulted in the wellproven Abart GTC technology. The Abart is a
two-stage counter-current process, even
though the stages internally operate in co-current mode. This principle reduces the effects
of moderate variations in upstream conditions,
such as varying fluoride concentration as well
as alumina flow and quality. The operating
mode is as follows. Fresh alumina is injected
into the gas in the filter stage, downstream of
the patented reactor where the pot off gases
enter the Abart. The high capacity fresh alumina is therefore used at the tail end of the
process, where the remaining fluoride concentration is low. This dramatically increases the
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structure, in most cases avoiding possible conflict with other equipment. The system consists
of a limited number of modules, thus reducing
stocks of spare parts and allowing for easy and
cost-efficient maintenance. These design elements make the Alfeed system ideal for both
new installations and for retrofitting.
Images: Alstom
Optimising GTC operating temperature
Fig. 1: Emal Gas Treatment Centre (GTC)
‘driving force’ for adsorption by the alumina,
resulting in a stable, low emission level. The
alumina from the filter is lead to the reactor,
where it is blended into recycled alumina. A
part of the recycled alumina is continuously
diverted back to the pots.
Alstom has developed a pot feeding system (Alfeed) (Fig. 2) that brings the fluorideenriched alumina from the Abart back to the
pots, thus replacing traditional crane filling
systems.
The Alfeed system is a further development
of the state-of-the-art alumina distribution arrangement that has been used in Abart systems for more than thirteen years. The Alfeed
pot feed system is a horizontal transport and
distribution system based on a supply-on-demand concept. It employs a boiling-bed fluidisation air slide, which is located alongside the
pot room building. Alumina is discharged from
the fluoride enriched alumina silo into the
main air slide through a rotary feeder which
is followed by a fluidised control screen (patent filed) that removes oversize particles. The
main air slide distributes alumina along the pot
line. From this air slide the enriched alumina is
distributed to the pots by means of individual
pressurised air slides. These have outlets that
enable each pot hopper to be filled as alumina
is consumed. Valves are operated during shutdown or maintenance only. The pots and pot
point feeder system are always filled with alumina. Fine dust is separated from the main air
slide and is fed directly to the individual pots.
The system is completely enclosed and the exhaust air is led into the collecting gas ducts for
the Abart. Thus the fines are contained within
the system and are distributed evenly among
the pots. The slim profile of the Alfeed design
integrates well with the top of the pot super-
Fig. 2: Alfeed system
Fig. 3: Relative HF emission versus gas temperature
40
As pot gas temperature rises above 100 °C,
there is a sharp rise in fluoride emissions from
the GTC, as shown in Fig. 3.
With the new high-amperage pots the gas
temperature increases from formerly about
140 to around 180 °C, which makes it even
more difficult to meet the new, low emission
limit values. For this reason, a number of
smelters have already had difficulty staying
in compliance during the summer. The traditional way of cooling high-temperature gas is
to bleed-in ambient air to cool it to acceptable
gas treatment temperatures (110 to 115 ºC).
However, with an ambient temperature of
up to 50 °C, this dilution may increase the
throughput of the GTC by more than 50%,
and increase the fan power requirement accordingly. Also, the additional filter bags increase maintenance costs.
Installing a heat exchanger to cool the off
gas is an alternative solution that not only reduces the size of the GTC, but also makes large
savings in the main fan power consumption
and also reduces in total HF emissions. In addition, the value of the recovered heat energy
alone can justify the added investment cost of
the heat exchanger. In the event that not all of
the heat energy is used, and part is vented to
the atmosphere through dump heat exchangers. However, fouling from scale formation has
been the main reason for the failure of heat exchangers in this application. In particular, the
cross-flow type has been tested for pot gas.
Control or elimination of heat exchanger fouling on heat exchanger
surfaces has been the
main driver behind
Alstom’s
development of the new fire
tube heat exchanger.
Alstom has long-term
experience with fire
tube heat exchangers
on similar or more difficult flue gases, such
as from Fe/Si- and
Si-metal
furnaces.
The fire tube heat exchanger (HEX) may be
arranged in the duct-
SPECIAL
ing between the pots and the GTC, or it may be
integrated into the Abart. The dust-laden hot
gas feeds into several parallel, straight tubes
immersed in water that cools the outside of
the tubes. The water flows in counter-current
to the pot gas from bottom to the top when the
HEX is arranged vertically, and consequently
the gas is cooled as it flows through the HEX
tubes from top to bottom. The counter-current
flows achieve optimum cooling at reduced
cost. This type of heat exchanger has reduced
fouling, and the thickness of deposits stays in
a stable, thin self-cleaning state. Several HEX
have been tested at Alba and Alcoa Mosjøen.
The version integrated (IHEX) to Abart is
shown in Fig. 4. The HEX is now available for
commercial projects.
The recovered heat may be used for district
heating or cooling, or for sea water desalination or for electric power production. District
heating is obviously a choice for colder cli-
Fig. 4: Integrated heat exchanger (IHEX) into Abart
mates, whereas absorption chillers could be
wisely used to generate cool air especially in
hot climates, such as for the Middle East and
Asia. One particularly interesting application to
cool inlet air to on-site gas turbines. This may
boost the power output of the turbine significantly (10 to 25%) during summer conditions.
Thermal desalination plants are another option that typically requires relatively low temperatures < 120 °C for heating of the process
salt water ‘brine’ to avoid excessive corrosion.
The principle is shown in Fig. 5.
This gives a near perfect match for the
recovered heat. Even the quantity of the recovered energy, which may exceed 100 MW
in these locations, is typically no problem to
consume in a desalination plant. Power production from low-temperature sources may be
through the Organic Rankine cycle, where the
hot water, steam or oil carries the heat energy
to be converted to electric energy. The efficiency of these machines is modest at low temperatures, but may become attractive as the
energy cost increases. The amount of energy
available for use depends both on the temperature difference between the pot gas and the
42
heat sink. This process is typically applied
for low-temperature
sources where part of
the energy is used as
district heating in the
cold season, and more
energy is converted
to electricity in the
hot season when the
demand for heating is
less.
Fig. 5: Example of deployment of heat energy
Sulphur dioxide abatement
Also the typical sulphur dioxide emission
from the pot is increasing, because of higher
sulphur content in the petroleum coke used to
make anodes, which is going up typically to
3 to 5%. Thus there is an increasing need to
remove sulphur dioxide to comply with emissions limit values. Such limits are already enforced at smelters in Scandinavia and in parts
of North America. New smelters starting up
in Qatar and Abu Dhabi will have sulphur
dioxide abatement system. Alstom pioneered
the development of sulphur dioxide scrubbers
for the pulp and paper industry, and later also
for power plants. Today there are several processes available to remove sulphur dioxide.
Absorption in an alkaline solution is an alternative for inland aluminium smelters without
access to seawater. A typical strong alkali absorbent is sodium hydroxide. This permits a
compact design and good absorbent utilisation.
For smelters located on the coast, scrubbing
with seawater is an excellent alternative. It
exploits seawater’s inherent acid buffer capacity. The sulphur dioxide is transformed into
sulphate in the scrubber process. Sulphate is a
harmless and natural constituent of seawater.
Depending on recipient conditions and on local regulations, aeration of the effluent may
be required to speed up a return to normal
pH value, and to provide for biological oxygen
demand. Both seawater and alkali processes
are extremely efficient, typically removing
more than 99% of the sulphur dioxide.
Decentralised distributed dry scrubber
The centralised Abart technology is now being
developed further to become the Decentralised Distributed Scrubber technology (DDS).
Traditionally the GTC is sited in the courtyard
between potrooms, and it is made up of identical compartments which can number as many
as thirty or more. These compartments operate
in parallel to optimise gas and alumina flow
and to secure operational flexibility. It is difficult to tune and operate these as well as to
detect failures or faults among the individual
units. As an alternative to the GTC, Alstom is
now launching the patented DDS, a solution
that divides the traditional GTC into smaller
sub-centres. These sub-centres are distributed
along the pot rooms instead of being placed
in between them. A typically DDS will handle
Fig. 6: Sunndal sea water flue gas desulphurisation
SPECIAL
gas from fifteen pots (~220.000 m3/h). As an
example, twelve DDS will replace one GTC.
This solution includes allowance for running
two of the pots simultaneously on forced draft
(~24,000m3/h) for each section.
The benefits of the DDS are many, but
there are also challenges and some disadvantages. For the discussion, the assumption is that
fresh alumina is stored in one central silo, and
the dense phase is transported up to each individual DDS. Now, DDS represent a significant
saving in power consumption, due to less ducting compared with a GTC. This reduces the
pot gas pressure drop for a DDS set by about
15% compared with the equivalent GTC.
However, as the DDS is closer to pots,
the pot gas temperature may be about 15 to
20 °C higher. The higher pot gas temperature
yields a significantly higher heat energy (about
50 kW per pot), since the heat is recovered
in the integrated heat exchanger. This mode
of operation ensures the optimal temperature
for fluoride recovery. The DDS provides enhanced operational flexibility, because each
DDS compartment can be individually finetuned through frequency-controlled drives
on the gas flow exhaust fan, and matched for
fresh alumina feed and for enriched alumina
recycling. To handle higher sulphur dioxide
concentration in the pot gas, a wet scrubber
may optionally be integrated into the top of
the DDS. There is a choice available between
an alkaline solution or seawater.
Alumina storage and handling is integrated
into the DDS. The fresh alumina storage is
normally sufficient for two days of pot consumption. From the DDS the fluoride-enriched
alumina may be fed directly to the pots through
the Alfeed system. This avoids intermediate
silos and alumina transfer points which tend
to increase alumina segregation. It increases
robustness as there are less transports. It also
saves significantly on equipment cost for alumina transport and for silo fluidisation.
The overall steel weight of the DDS arrangement generally saves 30% compared
with a GTC. DDS also simplifies the total
electrical layout, and it operates on medium
voltage (440 V), compared with a GTC which
needs substations for both high and medium
voltage. However, each DDS will have to be
electrified from a central source, which means
the number of power and instrument cables
will increase for a DDS arrangement. On the
other hand the number of monitors is reduced
by extracting gas from each mini-stack into a
laser-based analyser. HF and dust measuring
equipment is easily accessed from the filter top.
The DDS may be fully shop-manufactured,
as the size of a DDS compartment meets road
Fig. 7: Årdal Decentralised Distributed Dry Scrubber
transportation requirements. Shop fabrication ensures a uniformly high quality of work.
Several DDS can be erected simultaneously
and independently. This also allows for stepwise smelter expansion. The bolted design
eases the installation in an operating smelter,
since strong magnetic fields can disturb assembly by welding. Civil work for a GTC installation is a significant part of total cost. The
GTC foundations for the heavy silos, for filter
compartment support and for main fans are extensive compared with simpler and lighter arrangements for the DDS. Finally the footprint
is reduced to half. One DDS requires approx.
90 m2. Thus twelve DDS will take almost
1,100 m2, while the corresponding GTC needs
about 2,300 m2.
Removal of tar, fluorides and dust from the
baking furnace gases is traditionally handled
in a FTC with Abart technology. A conditioning tower cools the gas ahead of Abart for
efficient capture of tars and PAHs. Alstom intends to replace the conditioning towers with
its emerging heat exchanger for condensables.
This, combined with the DDS technology, constitutes a cost-efficient new FTC technology,
which includes heat recovery and improved
tar control.
Summary and conclusion
For more than 50 years Alstom has served
the aluminium industry through continuous development of air emissions abatement
technologies. The GTC size has increased significantly over recent years to match the ever
larger smelters. The current innovative heat
exchanger technologies optimise the off gas
temperature for better fluoride recovery in
the GTC so as to meet the gas emission challenge of new high amperage pots. These heat
exchangers may be installed in the flue gas
duct at the pot, or before the GTC, or be costefficiently integrated to the GTC. Depending
on the smelter location, the recovered heat energy may optionally be deployed for district
heating, or for driving a cooler, or for de-salting sea water. The Alfeed system closes the
fluoride-enriched alumina feed loop back to
the pots. This demonstrates that the principles
of centralisation do not always reduce cost and
ease operation of a system. The DDS solution
has many advantages and benefits. It reduces
cost and power consumption, and in addition
it reduces total footprint by 50% and combines
optional waste heat recovery. DDS has the
flexibility and operational performance that
will meet future emission requirements. Incorporating a sulphur dioxide scrubber in the
DDS system makes it a cost-efficient, multipollutant gas treatment technology. Alstom’s
new and emerging technologies contribute
significantly to the sustainability of the aluminium industry as the smelters grow further
in size and output. For these reasons Alstom is
the natural choice for complete environmental
and power-generating solutions to the aluminium industry.
Author
Bo Herrlander is global marketing manager Industry
& Power of Alstom Power, based in Växjö, Sweden.
Contact: [email protected]
43
ECL – renowned equipment supplier
to the primary aluminium industry
Since its inception in Lille, France, in
1947 ECL has become a world leader in
the provision of key equipment for the
production of primary aluminium. The
company is part of the Rio Tinto Alcan
group and its products are used in the
reduction, carbon and metal areas of
smelters. The product range is centred on
pot tending machines, cranes and transfer equipment for the reduction lines. It
further includes a wide range of products
and services for the carbon sector including green and baked anode handling
equipment, together with specialised
cranes, complete anode rodding shop,
and metal and bath handling systems. The
involvement of ECL does not end with
the conception, production, erection and
commissioning of its products. The company offers a wide range of supporting
services including training, technical assistance and the provision of spare parts,
as well as on-site maintenance management, equipment audits, refurbishment
and upgrades. The machines are adaptable to all the reduction technologies used
in today’s smelters.
To be closer to its customers – more than 150
plants located worldwide – ECL set up eight
subsidiaries around the world. The first one
was opened in Quebec in 2000. The following
year saw the establishment of three more operations – ECL Services Africa Engineering in
Richards Bay, South Africa; ECL Services Nl.
Bv. in Vlissingen, The Netherlands, and ECL
Services Pty. Ltd. Australia, based in Brisbane
and Portland. In 2002, ECL Africa opened an
office in Maputo, Mozambique, and in 2003
a subsidiary in Shanghai, Republic of China.
In 2006, a project office was opened in India.
2007 has seen the opening of a new office in
Dubai, UAE.
The advantages of having offices close to
its main customers are obvious. ECL provides
fast and efficient services on a 24/7 basis. Customers benefit from on-site after-sales services,
from refurbishment or upgrade services, and
from technical support and maintenance.
Images: ECL
A.-G. Hequet, ECL
Anode rodding shop
dedicated to the manufacture of equipment
specifically for the primary aluminium industry. The company’s flagship product is doubtless the pot tending machine (PTM) which
this year celebrates its 50th anniversary. More
than 1,150 PTMs have been sold in fifty years.
Innovation
A wide range of products and services
Reduction: ECL prides itself on being entirely
44
Each model is adaptable to all the reduction
technologies used and it is designed to match
each smelter’s specifications. The ECL cranes
benefit from many patented or patent pending
innovations.
Pot equipment is a significant part of the
company’s offer, with more than 15,000 pots
equipped by ECL worldwide. This sector includes anode beam raising mechanisms, anode
jacking frames, crust breaking and feeding devices, J hooks and fixings, anode clamps and
sealing jaws.
Carbon: ECL offers equipment for the
whole carbon sector, from single machines to
turnkey rodding shops (including the building)
for all types of anodes. Around the world the
company has installed 190 furnace tending
assemblies, 28 anode rodding shops and 15
anode handling and storage shops.
Metal: ECL also provides its customers
with metal handling systems for both potroom and casthouse. Fifty years have gone by
since ECL commissioned the first pot tending
machine in the French Rioupéroux smelter
(closed in 1991), thus leading the mechanisation of the aluminium smelter industry. Fifty
years of innovation, research and development to improve performance in terms of
commissioning time, productivity, availability
rate, safety, impact on the environment and
reliability. Fifty years during which the
PTM has become lighter and more compact,
equipped with new tools and radically new
options such as the new pot hood handling
device, which is operating with great success
in modern smelters around the world. Fifty
years of collaboration with AP Technology
in order to constantly increase efficiency and
safety of every single smelter.
Fifty years of taking into account smelters’ needs and achieving significant capex and
opex savings over contemporary designs.
ECL pot tending machine of the latest generation
ECL is also renowned for introducing innovative concepts to the industry. Amongst recent
technological advances are the potline shutdown and restart solutions.
Shutdown and restart solutions: After
accidental shutdowns, many potlines have
been unable to restart without total relining
lasting many months. Still today, whatever
SPECIAL
it, to increase productivity, and to make sure
the equipment meets the ever increasing environmental and safety requirements.
Project Management
Another ECL strength is its team of project
managers dedicated to overseeing the manufacturing and installation phases of each piece of
equipment. The manager coordinates the work
of all the teams contributing to the project, both
inside and outside ECL, until the equipment
is operating to the terms of the contract. The
project manager is also responsible for seeing
that the project is delivered both on time and
to the agreed cost.
More than just offering products, ECL
prides itself on delivering solutions in order
to assist its customers at every step of their
project and at every milestone of any equipment’s life cycle.
Shutdown and restart tools
Dual air compressor
the technology for aluminium electrolysis,
reduction pot shutdown and restart, planned
or unplanned, remain extremely critical operations, especially due to the need for human
intervention.
During the shutdown phase the operator
must manually use mechanical tools to introduce short-circuiting wedges between the
electrical conductors, so as to by-pass the current to the following pot, and then later he
must remove the wedges to restart the pot.
The working area situated about one metre
below the floor level is quite confined, and
it puts the operator in a very uncomfortable
and hazardous situation where he is at risk of
serious injuries.
Furthermore, speed is of the utmost importance. If the wedges are not removed fast
enough during the restart phase, the high current density may produce electrical arcs which
can damage the conductors.
Therefore to reduce conductor maintenance costs, but above all to put the operator
in a safe working environment, ECL along with
AP Technology, designed a remotely-controlled wedge extraction system which is entirely
operated from the working level and is connected with the pot tending machine.
This is only one result of a programme
which has seen 30,000 hours devoted to research and development.
Dual air compressor on PTM: Another instance of bringing value to the customer is the
development of a twin air compressor which
provides both energy saving and backup capability. Since the first pot tending machine commissioned by ECL, all the new options, tools
and technical solutions have been conceived
and designed with the sole aim of meeting Author
smelters’ challenges, to reduce energy consumption and consequently allow significant Anne-Gaëlle Hequet is external communication
cost savings, and to ensure safe and secure manager of ECL, based in Ronchin, France.
operations.
In close collaboration
with a world-class air compressor designer and manufacturer, ECL has therefore
developed and equipped
its pot tending machine
with a new standard of
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air compressor: the twin
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having just one big energyLWSRVVLEOHWRSURGXFHJUHHQDQRGHV
intensive compressor, the
ZLWKKLJKJUHHQDQRGHGHQVLW\DQG
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lighter compressors, which
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are used separately most of
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the time (anode changes),
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except when tapping off
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Improvements for the operation of anode baking furnaces
D. Maiwald, D. Di Lisa and P. Mnikoleiski, Innovatherm
refractory
• Performance of firing equipment for
combustion
• Performance of automation, control and
communication.
Images: Innovatherm
Improvement for the
lifetime of furnace refractory
Fig. 1: Fire arrangement ProBake on an open pit anode baking furnace
This paper discusses some important
aspects of how to optimise the firing
equipment to improve the operation and
performance of the anode baking process, with emphasis on the following major
topics: the improvements for the lifetime
of furnace refractory, the performance of
firing equipment for combustion and the
performance of automation, control and
communication.
The performance of an anode baking furnace
is strongly influenced by the availability and
reliability of the installed firing equipment.
Design and construction of key components
have to take into account the severe environment in and around an open pit anode baking
furnace. Another specific constraint is, that the
Fig. 2: Temperature distribution around a ‘hot spot’
on low velocity burners
46
mobile equipment must be moved every 24 to
26 hours, and it is consequently exposed to a
high rate of wear and tear. So all process disturbances which are related to the corporate
firing equipment can have a very high impact
on production quantity, quality and operational safety. Fig. 1 shows mobile burners and
exhaust pipes for a typical fire arrangement on
an open pit anode baking furnace.
This paper highlights some important aspects of how to optimise the firing equipment
to improve the operation and performance of
the anode baking process, with emphasis on
the following major topics:
• Improvements for the lifetime of furnace
Fig. 3: High velocity low NOx burner
The lifetime of the furnace refractory is primarily influenced by thermal stress. The thermal
stress is caused by the type of burner introducing the fuel between the flue walls. Low velocity burners at continuous or slow pulse operation cause peak temperatures and hot spots on
the refractory causing wear and resulting in
high maintenance, repair and replacements intervals. Fig. 2 shows a typical hot spot scenario
on a low velocity burner arrangement.
Improvement no. 1: high velocity low NOx
burner. The latest ‘high velocity low NOx burner’ technology provides a sophisticated flame
characteristic which is finally responsible for a
smart, controlled heat distribution within the
flue walls. The access to a defined heat distribution below the critical refractory temperature range also results in maximum controlled
energy efficiency and a very low temperature
deviation within the anodes themselves. Fig. 3
shows the special Innovatherm burner design
for this application.
The specific fuel gas injection at a speed
of 360 m/sec, achieves complete combustion
resulting in the best fuel efficiency as well as
in a homogenised waste gas for the following
burners and the downstream combustion of
volatiles escaping from the green anodes. Fig. 4
shows the same temperature plot after installation of the high speed burner technology.
Improvement no. 2: flue condition module.
Fig. 4: Temperature distribution with high speed
burner technology
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Fig. 5: Exhaust ramp with soot deposit
Fig. 7: Long life burner (Innovatherm)
The furnace refractory is exposed to thermal
stress from day one of production. The manual
inspection of the condition of each flue after
each fire cycle is a big maintenance issue. The
latest technology called ‘flue condition module’ collects all measured process values from
the firing equipment and verifies abnormal
conditions. A highly sophisticated fuzzy logic
module indicates analogue variations of individual flue wall conditions according to the
various control parameters so as to maintain
production targets. The module also produces
a ‘flue wall quality index’ which automatically indicates the condition of the refractory
of each flue wall and
finally modifies the
related heating regime
for each specific flue.
The flue condition
module output results
in a better flue wall
protection against peak
temperatures and consequently in less flue
wall maintenance sequences.
Performance of the
firing equipment
Fig. 8: Long life solenoid gas pulse valve (Innovatherm)
Fig. 9: Measurement drift of different types of thermocouples over operation
hours
48
Less cleaning cycles.
The combustion quality is only affected by
the performance of the
firing equipment. Poor
combustion results in
soot deposits, which
will require regular
maintenance for intensive cleaning of the
exhaust manifolds as
well as the ring main
ducts and filter equipment. Fig. 5 shows an
exhaust ramp at poor
combustion quality.
The controlled combustion at the burner
ramps and the highly
sophisticated oxygen
management
result
in complete fuel and
volatile combustion, so
that the exhaust ramps
as well as the main
ducts right through to
the fume treatment
plant remain clean of
Fig. 6: Exhaust ramp at optimised combustion
excess soot and unburned pitch. This avoids
all related maintenance and cleaning procedures. Avoiding cleaning procedures will also
lengthen operation times and therefore reduce
running costs and lower long term investment
costs. Fig. 6 shows the boot and damper of the
exhaust ramp on optimised combustion condition.
Long lifetime of the burner: The high velocity, low NOx burner is especially designed for
use in the anode baking furnace. The material
used as well as the proven design ensures a
long operation time, even when exposed to
the severe conditions of furnace atmosphere
and temperature. The expected operation lifetime will be more than five years. Since the
first operation start (1999) all of the installed
burners are still in operation and they perform
much better than ever expected. Fig. 7 shows
a burner after five years of operation without
any maintenance. Customers’ long-term experiences concerning performance and maintenance aspects are in all respects positive.
Long life solenoid valves: Due to the very
high pulse frequency required for efficient
burner operation in the baking furnace, Inno-
Fig. 10: Thermocouple Type S with SIC tube
SPECIAL
vatherm developed a long-life solenoid valve
especially for this application. A standard solenoid valve available on the market lasts for approx. 4 million operation cycles at maximum.
Innovatherm’s long life solenoid valve delivers more than 500 million (!) operation cycles. This ensures an almost maintenance free
operation with an average lifetime of more
than 12 years at a very critical point of the
process, as shown in Fig. 8.
Temperature measurement in the flues:
All anode baking staff all over the world describe the temperature measurement inside
the anode baking furnace as a constant maintenance issue. Normally people use
thermocouples Type N with stainless
steel protection tube. These have to
be replaced on average every four
months. And this not only because of
the wear of the stainless steel protection tube, but also due to the enormous measurement drift of the type
N thermocouple as shown in Fig. 9 at
operation temperature of 1180 °C.
So hundreds of thermocouples
have to be checked and changed per
year, which becomes an intensive issue in maintenance and cost.
As also can be seen from the diagram above: the thermocouple type
S is the only one which performs adequately in the operation temperature
range of up to 1250 °C. This is why
Innovatherm designed a special long
life Silicon Carbide protection tube
(SICsheath) which withstands thermal shocks and constantly changing
temperature over a very long period
(operation time of several years). By
combining a low drift thermocouple
with a long life protection sheath, the
average lifetime of this temperature
measurement was improved to more
than four years. As a result clients are
benefiting reduced overall running
costs as well as minimised maintenance frequency and so realising an
enormous operational advantage. Fig.
10 shows this type of thermocouple.
Auto zero pressure transmitter:
The continuous measurement and
control of the negative flue pressure
is essential for the performance of
the anode baking furnace. Usually
these pressure transmitters have to
be checked and recalibrated on a frequent basis to maintain the required
accuracy.
To minimise calibration maintenance, the pressure transmitters used
on the exhaust ramps, as well as on the measurement and zero point ramps, are equipped
with an auto zero calibration. The auto calibration function is triggered when energising of
the unit as well as every hour, to ensure fully
automatic recalibration of the unit. This function reduces to almost zero the specific maintenance activities for this calibration and improves the quality of control tremendously.
Automation control and communication
Wireless and Ethernet communication: The
anode baking furnace is embedded in a rough
ambient area. This coal dust environment is a
big risk for sensitive equipment and for the
whole communication system via network cables and plugs. This is a major maintenance
issue. The only adequate solution therefore
was to develop a complete wireless communication within the anode baking area. The
communication is now moved into a clean and
safe background location requiring much less
maintenance activities.
Duplicate process control: A standard
control system always contains at least two
PC stations running two independent, fully
identical ProBake programmes. This dupli-
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49
one PC fails, the second (redundant) PC
takes over the control
within less than one
minute, without any
interruption and on
full performance. The
maintenance team has
now plenty of time to
repair or reconfigure
the defective PC. Fig.
11 shows the duplicate PC equipment in
the operators’ room
of the baking area.
Fig. 11: Duplicate control PC equipment for ProBake firing system
cate control architecture is designed to ensure
the maximum operation availability. In case
Summary
This paper indicated several technological
parts of an anode baking process to address
briefly the problems of the operation and
possible improvements. All inventions and
modifications as shown are the results of
carefully designed technologies and longterm testing. Intensive communications with
customers, frequent after sales visits and appropriate production observations have continuously improved the design and abilities,
ensuring optimised product performance in
all aspects of customers expectations.
Authors
Detlef Maiwald is managing director, Domenico Di
Lisa is sales director and Peter Mnikoleiski is senior
process specialist of Innovatherm GmbH + Co. KG,
based in Butzbach, Germany. Contact: dmaiwald@
innovatherm.de
Testing cell controller algorithms using a dynamic cell simulator
M. Dupuis, GeniSim Inc.
The two main tasks of an aluminium reduction
cell controller are firstly to collect and process
the raw cell amperage and voltage, and then
secondly to use that information to manage
the cell efficiency. For this it must send instructions both to the point breaker feeder in order
to control the dissolved alumina concentration
in the bath, and to the anode beam to control
the Anode Cathode Distance (ACD).
There is obviously a major advantage to be
able to test a modification to the cell controller algorithms using a simulated cell instead of
putting real cells at risk. This is true as long as
the behaviour of the simulated cell is realistic
enough to provide reliable feedback. In order
to achieve that goal, the Dyna/Marc cell simulator has been continuously improved since
1994. It has already demonstrated its ability to
reproduce measured cell dynamic evolution,
as shown in previous publications [1, 2].
release. The level of the added noise is function of the ACD, the thickness of the metal
pad, the amount of sludge and the fraction of
the anode surface covered by frozen bath. This
noise level, which can be made to affect current efficiency, can be reduced by automated
voltage treatment since version 1.4 issued in
1999.
The cell controller cannot directly use the
noisy cell voltage to calculate the slope of the
cell resistance, since this would lead to useless results. Since version 13.0 issued in 2011,
Dyna/Marc offers linear and quadratic Root
Mean Square (RMS) noise filtration algorithms
[3]. Fig. 1 shows the comparison between the
noise-free and the noisy evolution of the cell
pseudo-resistance, which is the slope of the
voltage/current curve. The purpose of the
noise filtration algorithm is to allow the cell
controller to use the noisy data so as to estimate the evolution of the slope of the noisefree curve. This slope can serve to estimate
percent dissolved alumina and so to control
the feeding rate. Fig. 2 compares the target
noise-free slope evolution with three estimates
of the slope evolution estimated using three
Fig. 1
Since version 1.0 issued in 1998, the Dyna/
Marc has offered the option of adding noise to
the amperage and voltage tracks in the simulation. For the cell voltage that noise is an output from the simulation. Thus at the end of
each time step noise is added to the calculated
noise free-voltage to present disturbances by
the bath-metal interface motion and by bubble
50
Images: GeniSim
Testing cell voltage noise
filtration algorithms
SPECIAL
different mathematical modes of noise filtration applied to Fig. 1.
In Fig. 2 the first curve on the left results
from linear RMS fitting using 60 datapoints
that are themselves each an averaged value
of the raw cell voltage measured over 5 seconds at a 10 Hz frequency. As can be seen,
the resulting estimation is still a bit noisy. The
second curve in the middle results from using 120 datapoints instead of 60 datapoints.
The result is almost noise-free, but now the
estimation is lagging 5 minutes behind the
noise-free target slope that is being estimated.
This is to be expected, as it is the best linear
fit of cell voltage evolution using the last 10
minutes of datapoints collected, so it best represents the state of the slope 5 minutes ago.
In the example presented in Fig. 2, the slope
doubles in 5 minutes during a no-feed observation, so the estimated value is noise-free,
but it is about half of the real value. The third
mode of filtration on the right of Fig. 2 shows
the result of quadratic RMS fitting, also using
120 datapoints. Quadratic RMS fitting of the
cell voltage evolution eliminates the drag in
the slope estimation, which is important, but
for the same number of datapoints used, RMS
generates a more noisy estimation.
of the slope of the cell pseudo-resistance in
blue. It also presents the estimated slope evolution that results from using linear RMS fit-
ting with 60 datapoints, each datapoint being
the results of 5 seconds cell pseudo-resistance
evolution averages. At that time scale, the 2.5
Fig. 2
Fig. 3
Testing feed control algorithms
These days, the majority of algorithms used
to control alumina feed in aluminium reduction cell are based on continuous tracking or
else on underfeeding and overfeeding cycles,
where the shift from underfeeding to overfeeding is dictated by a trigger value, which is
based on either the slope of the cell pseudoresistance or the slope of the cell normalised
voltage. One of the earliest versions of that
algorithm can be found in Fig. 3 [4]. That
algorithm is available in Dyna/Marc simulator under the name Pechiney Tracking Feed
Control [5].
The basic concept that lead to the development of that algorithm was the observation
that the cell current efficiency is maximised
by operating very lean in alumina, and so
very close to the anode effect conditions. The
algorithm then takes advantage of the fact
that during underfeeding, the slope of the cell
pseudo-resistance starts to rise significantly
before the anode affect. Fig. 3 shows the results by running that feed control algorithm
in Dyna/Marc. The top graphic shows the 24
hours evolution of the cell pseudo-resistance.
Metal is tapped out at noon and anodes are
changed at 18 hours. It can be seen that the
cell is more noisy after the anode change. The
middle graph shows the noise-free evolution
Fig. 4
51
minutes delay of the noise-free pseudo-resistance evolution compared to the estimated
pseudo-resistance evolution is not noticeable,
Fig. 5
Fig. 6
Fig. 7
52
but it does affect the timing of the feeding regime shift. The third, lowest graphic shows the
feeding periods resulting from the algorithm
decision. The underfeeding rate is 70% of the
nominal feeding rate while the overfeeding
rate is 140% of the nominal feeding rate. The
overfeeding rate duration was set to 1 hour.
As a result, the resulting evolution of the dissolved alumina concentration in the bath in the
same graph varies from around 2% to around
2.5%, 2% being the alumina concentration
that would trigger an anode effect.
It is important to notice when the feeding
rate is increased that the alumina concentration continues to decrease by about 0.1% before starting to increase because the alumina
takes time to dissolve. That delayed response
will trigger an anode effect if the increase in
feeding regime is done too late; hence the importance of eliminating as far as possible the
delay in the pseudo-resistance slope estimation. Fig. 4 shows the resulting 24-hour averaged specific power consumption and current
efficiency: 12.96 kWh/kg and 94.71% respectively.
It is now well recognised that this type of
continuous tracking feed control algorithm
achieves significantly increased current efficiency over compared with feed control
algorithms which used a steady feeding rate
most of the time. It is also well known that
the shorter feeding cycle also increases current efficiency; this can be tested using the cell
simulator. Fig. 5 shows results obtained using a
shorter, 40 minutes overfeeding rate duration.
As a result, the dissolved alumina concentration only varies from around 2% to around
2.3%. This leads to a predicted improvement
of the current efficiency from 94.71% to
94.78%, and a slight increase of the specific
power consumption to 13.01 kWh/kg if the
ACD is kept constant.
The demand feed control algorithm developed by Kaiser and implemented in Celtrol cell
controller [6] is also available in Dyna/Marc.
The same reduction of the feeding cycle study
presented above can be repeated, this time using the demand feed control algorithm. Fig. 6
presents the base case results: 12.91 kWh/kg
and 94.67% current efficiency, while Fig. 7
presents results for the case with shorter feed
cycles: 13.09 kWh/kg and 94.65% current efficiency. Despite a very similar increase of the
feed cycles and reduction of the range variation of the dissolved alumina concentration,
the two algorithms predict different results on
the global process efficiency: the current efficiency is hardly affected and the specific power consumption increases more. The reason for
these differences is that with Kaiser algorithm,
it was not possible to maintain the same average ACD and operating temperature, which
both increased for the shorter cycles case.
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Developing and testing
new feed control algorithms
A dynamic cell simulator can be even more
useful for developing a completely new feed
control algorithm without putting real cells at
risk. One such innovative new feed control algorithm was recently tested using Dyna/Marc
cell simulator: it is the in situ feed control algorithm [3, 7-9].
The main innovation of the new in situ feed
control algorithm is that it can indirectly measure the concentration of dissolved alumina in
the bath during a no feed track. It does this
by numerically establishing the relationship
between the alumina concentration and the
slope of the normalised cell voltage. In fact,
that correlation is implicitly used in all continuous tracking algorithms that monitor the
slope of the pseudo-resistance (or the slope of
the normalised cell voltage) to decide when
it is time to shift from underfeeding to overfeeding.
The cell simulator can quite easily verify
that there is a unique correlation between the
concentration of dissolved alumina in the bath
and the slope of the normalised cell voltage,
and can numerically establish that unique correlation if it exits. Fig. 8 presents the results
by running the in situ feed control algorithm
in Dyna/Marc for 24 hours. A no feed-track is
called every 3 hours in order to evaluate the
dissolved alumina concentration. Fig. 9 shows
the correlation between the slope of the normalised cell voltage and the falling dissolved
alumina concentration. At the top of the hysteresis loop, the black line is the fit of the average path during the tracking, and all 8 tracks
follow the same trajectory. This is why the in
situ feed algorithm can use the equation shown
to establish the alumina concentration at the
end of each track. So there is a unique correlation, because each track starts from identical conditions, the conditions the in situ feed
algorithm is trying to maintain.
The second innovation at the core of the in
situ feed control algorithm is its use of the primary calibration surface [3], at the end of each
track, to estimate the ACD after it has estimated the dissolved alumina concentration. Then,
based on an estimated evolution rate of the
ACD, that same primary calibration surface
is used, together with an assumed ACD value,
to estimate every 5 minutes the dissolved alumina concentration from the cell normalised
voltage. Finally, a simple PID controller serves
to maintain the estimated dissolved alumina
concentration on its target value. In the example shown in Fig. 8, that target concentration
was set to 2.25%.
54
Fig. 10 presents the results of a second run,
calling for a track every 12 hours only, this
time with the normal anode change event that
was removed in the previous run in order to
keep things more simple. The corresponding
24-hour averaged specific power consumption
Fig. 8
Fig. 9
Fig. 10
SPECIAL
and current efficiency are: 13.02 kWh/kg and
94.77% respectively. Those results are quite
similar to those obtained using the continuous
tracking feed control algorithm with shorter
cycles, but with far less risk of having anode
effects.
Conclusions
The author hopes that this demonstration
study highlights the value of using a dynamic
cell simulator to optimise existing cell controller algorithms, and to test new ones, without
putting real cells at risk. The Dyna/Marc cell
simulator used in this study is available to the
whole aluminium industry through GeniSim
Inc. Version 13 included the linear and quadratic RMS noise filtration algorithms and the in
situ feed controller algorithm. The Dyna/Marc
cell simulator can also be used as a cell design
tool, as demonstrated in [10].
References
[1] I. Tabsh and M. Dupuis, ‘Process Simulation of
Aluminum Reduction Cells’, Light Metals 1996, ed.
W. Hale (TMS, Warrendale, Pa), 451-457.
[2] M. Dupuis, I. Eick and F. Waldman, ‘Modelling
Thermal Dynamic Response to a 3-Hour Total Power
Shutdown Event’, 9th Australasian Aluminium Smelting Technology Conference and Workshops, (2007).
[3] M. Dupuis and M. C. Schneller, ‘Testing In Situ
Aluminium Cell Control with the Dyna/Marc Cell
Simulator’, COM, (2011), to be published.
[4] Y. Macaudiere, ‘Recent Advances in Process
Control of the Potline’, Light Metals, 1988, ed. L.
G. Boxall (TMS, Warrendale, Pa.), 607-612.
[5] M. Dupuis and H. Côté, Dyna/Marc Version 13
User‘s Guide, (2011).
[6] K. R. Robilliard and B. Rolofs, ‘A Demand Feed
Strategy for Aluminium Electrolysis Cells’, Light
Metals, TMS (1989), 269-273.
[7] M. C. Schneller, ‘In Situ alumina feed control’,
JOM, 61(2009)11, 26-29.
[8] M. C. Schneller, ‘In Situ aluminum feed control’,
Light Metals 2010, ed. J. A. Johnson (TMS, Warrendale, Pa), 563-568.
[9] M. C. Schneller, ‘A new approach to alumina
feed control’, ALUMINIUM, 86 (2010) 9, 98-102.
[10] M. Dupuis and V. Bojarevis, ‘Retrofit of a 500
kA Cell Design into a 600 kA Cell design’, ALUMINIUM 87 (2011) 1-2, 52-55.
Author
Dr. Marc Dupuis is a consultant specialised in the
applications of mathematical modelling for the
aluminium industry since 1994, the year when he
founded his own consulting company GeniSim Inc
(www.genisim.com). Before that, he graduated with
a Ph.D. in chemical engineering from Laval University in Quebec City in 1984, and then worked ten
years as a research engineer for Alcan International.
His main research interests are the development of
mathematical models of the Hall-Héroult cell dealing with the thermo-electric, thermo-mechanic,
electro-magnetic and hydrodynamic aspects of the
problem. He was also involved in the design of experimental high amperage cells and the retrofit of
many existing cell technologies. Contact: dupuis@
genisim.com
Testing of carbon materials for research and industrial purposes
Markus W. Meier, Raymond C. Perruchoud and Jean-Claude Fischer, R & D Carbon
In 1986 Werner Fischer founded the new
company R & D Carbon by a management
buyout from Alusuisse, where he had headed
the carbon research group since 1966. With
a clear vision for the needs of the aluminium
industry, he had formulated the following
mission statement: “Through application of
our long experience and know-how in anode
technology and through our constant search
to improve anode quality, we at R & D Carbon
contribute substantially to lowering capital
investment for aluminium smelters and to reducing their operating cost.”
Together with his team, Werner Fischer
defined six areas of work, which are still in
operation today:
• Research and development
• Sales of laboratory test equipment and
numerous times, including several Light Metstandards
als awards [6-8]. Comprehensive handbooks
• Technical services
were published that are considered today as
• Bake furnace firing and control systems
indispensable reference books for every per• Technology development
son working in the carbon area or dealing with
• Training and conferences.
Fundamental research and development carbon related topics of aluminium smelters.
To pass on the findings of its extended
projects have been most important since the
research
and practical development projects,
foundation of R & D Carbon. In the past 25
R
&
D
Carbon
regularly organises training
years, seven PhD dissertations were completcourses
for
which
the company has gained a
ed in collaboration with universities in New
particular
reputation
and recognition.
Zealand, Switzerland and China. Their topics
The
international
training
course ‘Anodes
covered fundamental questions related to an–
from
Raw
Materials
to
Pot
Performance’
is
ode raw material characteristics and reactivity
organised
in
Switzerland
every
second
year
behaviour [1], to green mill operation [2], to
heat treatment during
baking [3], to anode
properties, and to anode burning, dusting
and cracking behaviour [4], as well as an
in-depth understanding of Chinese raw
materials [5].
The results of these
extended
investigations were published
as technical papers in
renowned
journals,
for which R & D Carbon was honoured Werner Fischer, the founder of R&D Carbon
Images: R & D Carbon
R & D Carbon Ltd operates a worldwide
unique pilot plant and laboratory to study
virtually all carbonaceous materials used
in the aluminium and steel industries.
Sophisticated research projects are conducted in parallel with extensive testing
of carbonaceous materials for a wide
range of customers. This paper reviews
the numerous activities and capabilities
of the technology centre located in Sierre,
Switzerland.
55
(the next course is scheduled for 8-12 October 2012) with participants from all over the
world.
Today’s focus of research
As outlined above, in the first two decades
since the foundation of R & D Carbon, the aims
of research activities were mostly to improve
the performance of smelter anodes so as to
reduce carbon consumption and thus cost of
producing aluminium. These investigations
Attendees of the 2010 training course in Martigny
are ongoing, as today’s changing quality of
anode raw materials (lower coke density and
lower QI in pitch) create new challenges that
the industry has to deal with.
With the introduction of graphitised cathodes in aluminium potlines, limited abrasion
resistance became the determining factor for
the pot life. This has activated a new research
activity of R & D Carbon to investigate how
alternative coke types can be used to make
graphitised cathodes with higher abrasion
resistance [9]. Currently various potential
alternatives are being tested that promise
significantly improved expected lifetime over
ordinary graphitised cathodes.
The steel industry is suffering from a shortage of needle coke to manufacture graphite
electrodes. Emerging countries such as China,
India and Russia produce and consume large
quantities of graphite electrodes. For this
they need ever more premium needle coke
with a low coefficient of thermal expansion,
as their steel industries install more ultrahigh-power Electric Arc Furnaces (EAF). But
western countries and Japan cannot supply
much more needle coke from their scarce feed
stocks of low sulphur decant oil. Therefore in
the years to come there is an urgent need to
develop and produce first class coke by delayed coking of coal tar pitch so as to respond
to the increased demand.
56
Pilot plant – from green coke
calcination to electrode graphitisation
ter machining the samples to 50 mm diameter
rods, the final step is to graphitise them. The
rods are placed in a lengthwise column for
graphitisation in an 80 kW pilot furnace. The
cores remain under pressure during the entire
process. The incremental change in length of
the sample provides vital information on their
puffing behaviour in the temperature range of
1 200 to 1 700 °C and on their graphitisation
pattern up to 3 000 °C.
Needless to say that R & D Carbon uses its
versatile pilot plant not only for research purposes, but also regularly conducts assessments
or optimisation trials as part of the technical
assistance to customers who manufacture or
use carbon products.
In its technology centre in Switzerland, R & D
Carbon operates a most advanced pilot plant
with a range of equipment that makes it unique
worldwide.
Pilot calcination: The choice of both calcining technologies and of the corresponding
calcination parameters are of primary importance for the calcined coke quality. In the
pilot plant of R & D Carbon, green coke can
be calcined either in
a rotary kiln or in a
shaft calciner. This
plant can produce up
to 20 kg per hour using appropriate heat Laboratory: Reference
treatment and resi- authority in carbon testing
dence time so as to
guarantee the correct When it comes to the characterisation of cardegree of calcination bon products, the test equipment installed in
for each of the differ- the laboratory of R & D Carbon does not leave
ent applications.
any questions open. Virtually the entire array
Preparation
of of carbon materials used for the metallurgical
green paste: The dry industry may be characterised using reference
aggregate is prepared methods, as the following roster shows.
through continuous
sieving in fractions Green coke / Anthracite Standard methods
and through continuous grinding in an air jet Ash content (%)
ISO 8005
mill. The paste is mixed either in an intensive Elements XRF (%/ppm)
ISO 12980
impeller mixer or in a sigma blade mixer. Sev- Hardgrove grindability index (-)
ISO 5074
eral batches are mixed with different amounts Sieving analysis (%)
ISO 12984
of binder so as to determine the best binder Volatile matter (%)
ISO 9406
content.
Water content (%)
ISO 11412
Pilot forming of carbon artefacts: Depend- Calcined coke and crushed butts
ing on the product type and application, the Air reactivity (%/min)
ISO 12982-1
paste is formed in a bench scale press (50 mm App. Hg density (kg/dm3)
DIN 66133
diameter), in a pilot scale press or vibrocom- Ash content (%)
ISO 8005
pactor (147 mm diameter) or in a 400-tonne CHON analysis (%/ppm)
ASTM 5291-02
extrusion press (80 mm rod).
ISO 12981-1
CO2 reactivity (%)
Pilot baking: The formed green carbon Crystallite size Lc (Å)
ISO 20203
items are baked in an electrically-heated pilot Elements XRF (%/ppm)
ISO 12980
bake furnace to a final
temperature between
1 050 and 1 250 °C to
remove the pitch volatiles and to increase
the real density so as
to achieve optimum
physical and chemical
properties of the final
product. For Søderberg applications, the
green paste is baked in
a dedicated Søderberg
baking furnace where
the paste is baked under pressure.
Forming area of pilot plant with vibrocompactor, extrusion press, pilot press
Graphitisation: Af- and bench scale unit
SPECIAL
Testing with high precision and capacity
Grain stability (%)
ISO 10142
Oil content (%)
ISO 8723
ISO 8004
Real density in xylene (kg/dm3)
Sieving analysis (%)
ISO 12984
Spec. electr. resistance (μΩm)
ISO 10143
ISO 10236
Tapped bulk density (kg/dm3)
Water content (%)
ISO 11412
Pitch
Ash content (%)
ISO 8006
Coking value (%)
ISO 6998
Elements XRF (%/ppm)
ISO 12980
Quinoline insoluble (%)
ISO 6791
Real density in water (kg/dm3)
ISO 6999
Softening point Mettler (°C)
ISO 5940-2
Toluene insoluble (%)
ISO 6376
Viscosity (mPas)
ISO 8003
Water content (%)
ISO 5939
Prebaked and Søderberg anodes, and butts
Air permeability (nPm)
ISO 15906
Air reactivity (%)
ISO 12989-1
Apparent density (kg/dm3)
ISO 12985-1
Ash content (%)
ISO 8005
Binder content (%)
ISO 14423
ISO 12988-1
CO2 reactivity (%)
Compressive strength (MPa)
ISO 18515
ISO 20203
Crystallite size Lc (A)
Dyn. elasticity modulus (GPa)
DIN 51915
ISO 12980
Flexural strength (MPa)
ISO 12986-1
Fracture energy (J/m2)
RDC 184
Open porosity (%)
ISO 12985-2
ISO 9088
ISO 11713
Static elasticity modulus (GPa)
ISO 18515
Thermal conductivity (W/mK)
ISO 12987
Thermal expansion (10-6/K)
ISO 14420
Cathode
Air permeability (nPm)
ISO 15906
ISO 12985-1
Apparent density (kg/dm3)
Ash content (%)
ISO 8005
Compressive strength (MPa)
ISO 18515
Dyn. elasticity modulus (GPa)
DIN 51915
ISO 12980
Flexural strength (MPa)
ISO 12986-1
RDC 184
Fracture energy (J/m2)
erate their own laboratory. But the test results
provided by R & D Carbon are usually broader
and are accompanied by an evaluation of current trends that are presented graphically. The
short lead time makes it also interesting for
plants, who could send the samples to their
corporate laboratory.
The third party opinion given in comprehensive reports is an important support for the
responsible plant personnel in their decisions
about raw material procurement and plant
operation.
Shipment certification and arbitration:
Together with Aminco Resources, R & D Carbon has developed a business model to produce ‘Swiss Anodes Made in China’. Stringent
specifications and technical support provided
by R&D Carbon, starting with raw material
selection and during the entire production, allows Aminco to offer world-class and consistent quality anodes. Since the late 1990s Aminco has supplied more than 1.5 million tonnes
of baked anodes to customers all over the
world. Samples of each shipment have been
analysed in the laboratory of R & D Carbon to
issue the quality certificate and to assure that
the anodes meet the specifications.
Many suppliers of coke, pitch and prebaked
anodes, but also of special products (such as
Søderberg briquets or ramming paste) appreciate the service of R & D Carbon for independTechnical assistance for a
ent certification of their product shipments.
broad field of customers
The quality sheet as part of the technical report
Indeed, R&D Carbon tests carbonaceous ma- brings an added value to their products, since
terials for customers with completely different the specific advantages which the producer
goals, but all of them rely on sound test results, claims become much more transparent.
often combined with clear recommendations
R & D Carbon is also regularly contacted as
for optimisation.
an independent party for arbitrage questions.
Routine analysis for aluminium smelters as Either suppliers or consumers send samples
part of a service agreement: Prebaked and Sø- for analysis to crosscheck whether products
derberg anode plants regularly send samples meet the specifications.
of anodes and raw materials for analysis of
Plant audits and optimisation trials: Every
the relevant properties at weekly, bi-weekly or major smelter decides at some stage to submonthly intervals. Often, these plants also op- mit its production site to an audit by an external party having
the appropriate experience. For audits of
the carbon area, R & D
Carbon has gained a
distinct reputation due
to the clarity of the information it provides
[10]. The systematic
methodology of R & D
Carbon involves taking samples at every
relevant
processing
step along the material stream, from the
The laboratory is kept clean and tidy to ensure impeccable testing conditions
at all times
anode raw material
Open porosity (%)
ISO 12985-2
Rapoport expansion (%)
ISO 15379-1
ISO 9088
Sodium vapour resistance (%)
RDC 192
ISO 11713
Static elasticity modulus (GPa)
ISO 18515
Thermal conductivity (W/mK)
ISO 12987
Thermal expansion (10-6/K)
ISO 14420
As well as the above mentioned carbon materials, R&D Carbon also analyses in its laboratory other special carbon materials, such as:
• Ramming paste
• Stub collar paste
• Søderberg briquets for Si arc furnaces
• Electrodes for steel production.
Sophisticated research equipment and corresponding techniques are applied to link the
macrostructure and bulk properties of the
carbon materials to their porosity, crystallinity and microstructure. Among them, X-ray
spectrometry and diffractometry, mercury
pressure porosimetry and microscopy image
analyser have been proven as very efficient
tools in the laboratory of R & D Carbon.
The combination of the long experience,
specific know-how and wide range of infrastructure allows R & D Carbon to give a real
added value to the technical services provided
to its customers.
57
notice. Such activities
may include a quick
evaluation of raw material. The procurement department of a
smelter may send some
coke samples of a new
supplier to check the
compatibility with the
existing raw materials.
In such a case R & D
Carbon conducts a full
analysis of the new and
of the reference coke,
followed by a bench
scale test which provides valuable information long before the
potential new coke is
Fischer today is as valid as ever. All employees
of R & D Carbon are dedicated to serve the industry by providing the best possible products
and services. For carbon testing, the address in
Switzerland is a first choice.
References
intake to the potrooms. These samples are
analysed in the laboratory of R & D Carbon
for the relevant properties. The comparison
of the properties with a vast database allows a judgement of each processing step
in relation to the worldwide average and
benchmark. Consequently, R & D Carbon can
quantify the potential for improvement at
every processing step based on neutral criteria.
As an outcome of the plant audit, the
smelter operator may decide that this justifies
a dynamic process optimisation in the paste
plant (DPO [11]) or bake furnace [12]. These
are very powerful methodologies to boost
production and product quality, often without
any investment in hardware. In either case,
the systematic tests conducted are based on a
large number of samples.
The samples generated during a plant audit
and during a process optimisation exceed by
far the capacity of an ordinary laboratory of
a smelter. Therefore these samples are analysed in the laboratory of R & D Carbon that
is equipped and prepared to examine large
amounts of samples.
Non-routine testing and evaluations: It
is evident that many activities of the laboratory occur on an irregular basis and at short
In 2011 R & D Carbon celebrated its 25th anniversary. From humble beginnings, the company now has a worldwide presence in the industry. A new generation of young engineers is
taking over important tasks in the business.
The mission statement defined by Werner
[1] Sheralyn Hume, ‘Influence of Raw Material
Properties’, R&D Carbon, Switzerland, 1993/1999
[2] Kirstine Hulse, ‘Raw Materials Formulation and
Processing Parameters’, R&D Carbon, Switzerland,
2000
[3] Felix Keller and Peter Sulger, ‘Baking of Anodes
for the Aluminium Industry’, R&D Carbon, Switzerland, 2008
[4] Markus W. Meier, ‘Cracking Behaviour of Anodes’, R&D Carbon, Switzerland, 1996
[5] Liu Fengqin, ‘Blending of Chinese Carbon Materials for the Production of Anodes for the Aluminium Industry’, R&D Carbon, 2004
[6] Werner K. Fischer and Raymond C. Perruchoud,
‘Influence of Coke Calcining Parameters on Petroleum Coke Quality’, Light Metals 1985, (TMS,
Warrendale, Pa.), 811-826
[7] Sheralyn M. Hume, Werner K. Fischer, Raymond
C. Perruchoud, James B. Metson and R. Terry K.
Baker, ‘Influence of Petroleum Coke Sulphur Content on the Sodium Sensitivity of Carbon Anodes’,
Light Metals 1993, (TMS, Warrendale, Pa), 535541
[8] Raymond C. Perruchoud, Markus W. Meier,
Werner K. Fischer, ‘Survey on Worldwide Prebaked Anode Quality’, Light Metals 2004, (TMS,
Warrendale, Pa), 573-578
[9] Raymond C. Perruchoud, Werner K. Fischer,
Markus W. Meier and Ulrich Mannweiler, ‘Coke
Selection Criteria for Abrasion Resistant Graphitized Cathodes’, Light Metals 2011, (TMS, Warrendale, Pa), 1067-1072
[10] Nils Einar Saue, Jon Ola Ystgaard, Jon-Inge
Johannessen, Markus W. Meier and Raymond C.
Perruchoud, ‘Improvement of Anode Paste Quality and Performance of Alcoa Lista’, Light Metals
2012 (TMS, Warrendale, Pa) to be published
[11] Raja Javed Akhtar, Saleh Ahmad Rabba, and
Markus W. Meier, ‘Dynamic Process Optimisation
in Paste Plant’, Light Metals 2006, (TMS, Warrendale, Pa), 571-575
[12] Vinicius Piffer, Ciro Kato, Markus Meier,
Raymond Perruchoud, and Peter Sulger, ‘Process
Optimisation in Bake Furnace’, Light Metals 2007,
(TMS, Warrendale, Pa), 959-964
Raymond Perruchoud, VP Research & Development:
“The trickier, the more interesting.”
Markus Meier, VP Technical Services: “We aim to
surpass customer expectations.”
Jean-Claude Fischer, Director: “Every day we strive
for continuous learning and education.”
Mobile laboratory shipped onsite for dynamic process optimisation DPO of
paste plant
58
processed in the plant.
Preliminary tests may be conducted when
a plant experiences problems in its potrooms,
such as a problem with carbon dusting or anode cracking. The information gained from
these tests often gives valuable indications to
help identify the potential root cause(s) of the
problem. This allows a much more efficient
resolution of the actual problem during the
subsequent plant visit.
Assuring testing accuracy: R & D Carbon
regularly conducts round robin tests to support other laboratories and to ensure the accuracy of their measurements. For owners of
laboratory test equipment from R & D Carbon,
a support service is available for maintenance,
repair and certification. This assures the comparability of the test results found on carbon
materials.
Outlook
SPECIAL
Anode handling and cleaning systems for modern aluminium smelters
K. Williams, Advanced Dynamics
Images: Advanced Dynamics
the system that ties all From the storage building, green anodes are
of the above independ- then conveyed and raised to the baking furent production plants nace operating floor, which is usually about
together is the anode six metres above ground level. From there, the
handling and cleaning anode handling system must re-orient the ansystem. Fig. 1 shows odes and group them into a suitable package
a simplified process for furnace loading by the FTA crane. Usually, the anode handling system will include
flow:
This anode han- a furnace central conveyor which will deliver
dling and cleaning sys- the packages of anodes adjacent to the furnace
tem is made up of the section currently being loaded. From the bake
following sub-systems: furnace central conveyor, anodes are picked
(a) the green anode up by the FTA and deposited into the approprihandling system, (b) ate section of the anode baking furnace.
the green and baked
After the green anodes have been processed
anode storage and through the baking cycle, the FTAs will remanagement system, move the now baked anodes from the bake pit
Fig. 1: Anode block production process
(c) the baked anode sections and deliver them to the baked anode
handling system, (d) handling system. Baked anodes coming from
the baked anode the furnace can be as hot as 450 °C and will
cleaning system, (e) be covered with loose metallurgical packing
ancillary equipment, coke. The baked anode handling equipment
(f) level 0, 1 and 2 inte- must be designed to handle the hot anodes
grated control systems and it must be able to work reliably with fallincluding the required ing coke deposits. Conveying equipment up to
wired and wireless in- the cleaning machine will be equipped with
terfaces with the GAP, either manual, semi-automatic or fully autothe FTAs, the anode matic packing coke recovery systems.
stacker cranes and the
If there are mixing problems in the GAP
rodding shop.
or if there are control problems in the ABF,
Green anodes com- then baked anodes can become stuck or fused
ing
from the paste together. An optional feature in a modern anFig. 2: Typical green roller conveyor in anode storage building
plant arrive at a steady ode handling and cleaning system is a baked
A modern aluminium smelter depends on the rate and are usually pushed onto a roller con- anode splitter (Fig. 4). The splitter is a selfcontinuous supply of the pre-baked anodes, veyor from the anode cooling conveyor dis- contained hydraulic press that will develop
which requires the following independent pro- charge system in the GAP. Roller conveyors, several tonnes of splitting force to ensure it
turntables, 90 degree pushers, etc. transport transmits only separated baked anodes for
duction and operation facilities:
the anodes and then
• The Green Anode Plant (GAP) which
accumulate them in
mixes the raw materials for carbon blocks
groups for storage in
and presses them into the proper shape
the anode storage fafor the given technology
cility. When a package
• A bake furnace plant including anode
of anodes is in position
bake furnace (ABF), Fume Treatment
for the anode storPlant (FTP), Furnace Tending Cranes
age crane, the anode
(FTAs) and firing systems
management system
• Green and baked anode storage facility,
will signal the crane to
usually fully automatic storage and
retrieve these anodes
retrieval using overhead cranes
and will provide the
(anode stacker cranes)
• The rodding shop – the plant that removes crane with the storage
address where it must
the spent carbon from the used anode
deposit them. See Fig.
stems and welds new stubs and fixes new
2 of a roller conveyor
carbon blocks to the cleaned-up stems for
running through an an- Fig. 3: Anode conveyors, elevators and manipulators delivering green anodes
return to the electrolytic cells.
to bake furnace
In a fully integrated and automated smelter, ode storage building.
59
Fig. 4: Anode splitter / separator
Fig. 5: Anodes in the baking furnace
delivery to the cleaning station.
Before the baked anodes can be sent to
storage or to the rodding shop, the anode
cleaning system must remove all the loose
packing coke adhering to them. This is done
in a series of three or four steps depending
upon the anode design. In the first step, the
anode is pushed through a set of hardened
steel scrapers that scrape the packing coke off
of two of the four vertical faces of the anode
block. In the second step, the anode is pushed
Fig. 7: Anode cleaner dust enclosure
60
through a second set of
scrapers (Fig. 6) which
cleans the remaining
two vertical surfaces
as well as the top
and bottom surfaces.
The third step is hole
cleaning which uses
a rotating tool and an
air blast to remove all
packing coke from the
anode stub holes. This
hole cleaning machine
can also be set-up to
machine the bottom of
the anode flat for optimal mating with the
anode stems in the rodding shop. Fig. 5 shows
how such anode hole
deformation can occur
in baking furnace.
The anode cleaning
machine with scrapers
and hole cleaners may
also incorporate a slot
cleaner if the anode
technology includes
slots (which help gas
to escape and so reduce anode effect and
increase potroom efficiency). These slots can
be pre-formed in the anode in the GAP. In
order to contain dust and collect the cleaned
off packing coke, the anode cleaning machine
will have a dust enclosure (as seen in Fig. 7)
and an associated dust collection system as illustrated in Fig. 8.
In a state-of-the-art automated system,
packing coke is collected and pneumatically
conveyed back to the bake furnace for re-use
in the baking process, and fine carbon dust is
collected and pneumatically conveyed back
to the GAP for recy-
Fig. 6: Anode scraper section
cling and re-use in making new green anodes.
Clean, baked anodes leaving the cleaning
machine are delivered to either baked anode
storage or to the rodding shop via elevators,
roller conveyors and other orientation manipulators such as turntables, pushers, etc.
Complete anode handling and cleaning systems are integrated with state-of-the-art control systems that conform to customer-specific
standards. In modern smelters where capacity exceeds 500,000 tpy, these systems can
comprise of 150 to 200 individual pieces of
equipment and thousands of I/O. The systems
communicate with the GAP, ABF and rodding
shop processes via an industrial control network. RF networking provides communication
with the anode storage cranes and furnace
tending cranes. The control system assures a
fully automatic process flow, and it is the key
component that ties all of the anode production processes together.
Author
Kevin Williams is the vice president of Business
Development at Advanced Dynamics Corp. Ltd.
He is a mechanical engineer with 24 years of experience in the design of mechanical and control
systems, project management and solutions architecture of heavy duty automated material handling systems for the aluminium industry. Contact:
[email protected]
Fig. 8: Dust collection system
SPECIAL
Smelter logistics upgrade
A. Wolf, Claudius Peters Projects
The primary aluminium industry is one of
the world’s most energy-intensive industries
and also one of the most polluting. The use
of aluminium can be largely attributed to its
light weight. Its specific weight of 2.7 g/cm3
is approximately a third of that of other common metals such as steel. In combination with
light weight, aluminium alloys can show very
high strength in comparison with many other
metals. In addition, the very good electrical
and thermal conductivity and optical reflecting make aluminium very attractive to various
industries.
Today the global economy imposes a more
severe competitive environment for aluminium production, requiring more efficiency
through the entire production process. Competitive pressures are increasing steadily together with the cost of materials, personnel
and transportation. Management must critically evaluate production processes to determine
their effectiveness in bringing maximum value
to customers at reduced cost.
Management for aluminium production
must also determine the best available technology and working practice to protect the
environment in compliance with local and
international laws. The energy and environmental constraints reconfigurate the value
chain in the aluminium industry, leading to a
T1
T2
T3
T4
T5
T6
–
–
–
–
–
–
Ship unloader entry
From ship unloader to primary silo
Alumina transport to primary silo entry
Alumina discharge from primary silo
Alumina charge to day silo
Alumina discharge day silo
T7 – Transport from discharge day silo to GTC / FTP
T8 – Alumina charge to secondary silo entry
T9 – Alumina discharge from secondary silo to entry potroom
T10 – Alumina distribution system in potroom
T11 – Alumina potfeeding
Fig. 1: Typical logistic overview material process chain with transition points (T1 – T11)
To systematically identify the area(s) with the
greatest potential for optimisation, we must
consider the many systems and identified
components of a typical aluminium processing
plant, which are joined to processing systems
with several transition points (Fig. 1). Each
transition point in the processing system can
have an effect – good or bad – on the quality
of the material process chain.
rapid increase in production cost. Stricter environmental regulations and the pressures to
reduce capital expenditure (capex) and operational expenditure (opex) direct us to look at
the entire production chain.
There are various factors forcing the management of the processing aluminium plant to
evaluate the plant performance. Listed below
are some major factors which influence the
value chain reconfiguration:
• Energy consumption
• Energy cost
• Product quality
• Raw material consumption
• Raw material cost
• High opex
• Strict environmental regulations
(reduced emissions output)
• Technology employed
(incompatible or outdated technology)
• New and more energy-efficient technology
• Production cost savings
• Equipment life cycle
• Replication (automation)
• Operator (labour cost and training)
• Increased competition.
Establishing project
requirements and objectives
Images: Claudius Peters
The fast-moving and growing global market, with its competitive pressures is forcing aluminium producers to raise output
and quality within a short period of time.
Smelters need to develop innovative tools
to evaluate and improve the current status of their process control and to measure, track and analyse the entire process
chain with all transition points. This will
help to operate the plant cost-effectively
and in an environmentally friendly manner. This investigation and analysis can
be vital to enable an aluminium company
to remain competitive in the industry and
it will guide the decisions for technical
improvement to and for investments in
state-of-the-art technology. The evaluation of the current status and of new
trends within the aluminium industry
typically requires strategic planning
through business development. This paper provides guidance for the decision
making process for current and future
plant activities.
Fig. 2: Unloading station
Typically, the need to upgrade or modernise
an aluminium plant is identified by the plant
management or a third party. An upgrade or
modernisation project should be treated as
any other project in terms of the formal application and approval process. The requirements
of an upgrade or modernisation project should
be written down in a project specification document. This document should include information about the project scope, estimated costs,
project schedule (implementation and time
frames) and priorities. It is essential to develop
and conduct a project cost / benefit analysis to
verify the overall budgetary estimate provided
in the project specification.
To understand the production plant process
in the logistic overview material process chain
a strong process and productivity analysis has
to be performed to investigate the current status of operation. The task is to identify and determine the performance of single components
and systems (breakdown) within the material
process chain using process flow sheets and
components and / or performance reviews.
Summarised: save costs by reducing the
production cost, increase the productivity,
improve the competitiveness, identify the unnecessary process steps in the workflow and
optimise the material flow.
©
61
Fig. 3: Pneumatic conveying transport
Case study and practical
considerations for upgrade projects
Transition point alumina unloading station: In
the production process there are many transition points, as shown in Fig. 1. In our case
study the alumina is delivered by train to the
alumina unloading station of the aluminium
smelter plant (Fig. 2). There is a known risk
of spillage during the handling of alumina. To
avoid alumina spillage it is important to use a
closed sealed discharge system for the material
transfer. Alumina spillage means material loss,
leads to dust development, pollutes the environment and is a large loss of investment.
Transition point pneumatic conveying: Either mechanical or pneumatic conveying systems can serve to transport alumina between
different plant areas. The advantage of pneumatic conveying systems is that they simplify
plant design and conveying routing, and that
they are closed and therefore environmentally
friendly.
Disadvantages compared to the mechanical conveying are that the system inherently
consumes higher power and tends to suffer
increased wear. Alternatively Fig. 3 shows the
‘Fluidcon’, a pneumatic conveying system that
substantially reduces these disadvantages.
A system for handling and transporting
alumina must be able to operate at extremely
low transport velocity and relatively low energy consumption. Specific technical targets
for the systems include:
• No grain abrasion and no grain fracture
• No increase in the portion of particles
< 45 mm, which is critical for further
processing
• No segregation according to grain size;
this means that the critical portion
< 45 mm must not accumulate during
transport or storage etc., neither spatially
nor over time
• Wear-resistant design and only low wear
during operation
• Dust-free operation
• Up-to-date energy saving technology.
The system must be able to start-up with full
conveying line and to restart conveying an interruption by, for example, a power failure.
62
point feeding is a fully functional control of
the alumina distribution process (Fig. 5) under
the constant control of key parameters (input/
output).
Feedback regulation of the cell ensures
optimum distribution, using signals from the
automated feeding system linked to the automated control system.
The alumina distribution system serves to
transport and distribute alumina and fluoride
to the pot superstructures in the potroom
(Fig. 6). Typically, a fume treatment plant is the
upstream interface. This distribution should
be an enclosed, self-regulating and unmanned
system.
Required is a controlled, smooth, uniform
and dust-free transport of the material. To improve its performance, control of the material
distribution should be supported by an automation system, ensuring that the cell pointfeeders inject just enough alumina at just the
right time.
The standard operating and control technology should include aan utomatic control
system, an operation procedure manual and
a supervisory management system.
Starting up with a full line will not be a problem with a state-of-the-art conveying systems
like Fluidcon (Fig. 4).
Existing systems already used in the alumina handling process have proven that such
restarts can be accomplished and they are
now a standard procedure in many aluminium plants today.
Transition point alumina storage silos:
The purpose of the alumina silo (Fig. 5) is to
store a large amount of alumina economically,
safely and reliably. The silo design depends
on the specified material and on the material
properties, such as grain size, particle density
and particle shape, fluidisation behaviour and
moisture content.
High capacity alumina storage silos are designed with the following features:
Implementation in plant
• dry and safe storage
operation and validation
• closed storage system
• automated controlled charging and
The principal strategy is to determine and esdischarging system
tablish a data validation process so as to con• uniform storage pattern
duct improvements in the entire process chain.
• maximum storage capacity utilisation
This will provide the measurement data and
• prevent excessive dust development
results which are the basis for selecting poten• avoid alumina segregation
tial improvements, and for choosing energy• maintain the grain size distribution
saving technology developed by the supplier
• maintain uniform flow pattern.
company. To improve performance, a supThe employed silo discharge technology en- plier company utilises in-house development
sures a safe, automated and therefore con- with own R&D support as well as outsourcing
trollable material flow into the process chain. to technology suppliers who provide proven
The silo design influences the amount of dust ‘packages’ for design, operating systems and
development and segregation. It will therefore training.
have an impact on the
alumina quality and so
determine the overall
silo performance.
Transition
point
electrolysis
feeding
systems: The main
challenge in improving the management
of higher amperage
pots is to ensure a precise and reliable automated alumina supply
to electrolysis cells.
Compared to existing
alumina distribution Fig. 4: Typical pneumatic conveying system equipped with conveying
systems,
transition pipe ‘Fluidcon’
SPECIAL
verification of inventory modifications are
estimated from the
current plant status
and the potential performance results.
Conclusions
Fig. 5: Alumina distribution systems
Capex financed plants often suffer from
poor support from their technology suppliers
(cheap and dirty), and therefore their opex is
very high. Such plants could benefit from the
opportunity to outsource individual design
work to specialist engineering companies. The
expected improvements and the necessary
Whether operating a
new state-of-the-art
assembled
production line or investing
in modern technology to modify existing equipment, it is Fig. 6: Potroom
imperative to record
the performance of plant systems and components. Such records will support the decision-making process for current and future
plant activities, especially with regard to investments in energy-saving technology developed by the technology and system supplier.
Author
Andreas Wolf is business development manager
Aluminium with Claudius Peters Projects GmbH,
based in Buxtehude, Germany. Contact: andreas.
[email protected]
Alliances in the aluminium industry
Three leaders of high-performing alliances from WorleyParsons share
their insights on achieving long term success for their customers
BSL
S. Clough, WorleyParsons
Boyne Smelters Ltd
Strategic alliances are often the method
of choice for strengthening an enterprise’s
position by increasing efficiencies and by
accessing new or critical resources. For
many asset operators, an alliance based
on sustainable capital works is an attractive way of achieving the business growth
they require. But with a high failure rate,
the viability of such growth strategies
depends critically on a company’s alliance
capability. Since the 1990s WorleyParsons has been heavily involved in alliances to deliver sustaining industrial projects
within the aluminium industry, and it is
considered a leader in this kind of alliancing within the resources sector.
Shane Burns, together with Danie Swemmer
on the customer side, manages the alliance for
Boyne Smelters Ltd (BSL), Australia’s largest
aluminium smelter, located near Gladstone
in Queensland. BSL was commissioned in
1982, and the operating plant has grown extensively since then. The smelter underwent
an AU$1bn expansion in 1997, introducing a
third reduction line which increased aluminium production from 260,000 to more than
558,000 tpy. BSL currently employs around
1,400 staff and contractors. WorleyParsons
has been an alliance partner since 2004.
Chris Lovelock is alliance manager at
Tomago Aluminium, one of Australasia’s leading aluminium smelters. Constructed in the
early 1980s, at the time of first production it
was the world’s first large-scale AP18 plant
in the world, with two potlines and a capacity of about 240,000 tpy. Tomago Aluminium
currently employs around 1,100 people and
produces 530,000 tpy of aluminium.
Ian Waterman was until recently the alliance manager at Hydro’s Kurri Kurri smelter,
which commenced operation in 1969 and is
located near Newcastle in New South Wales,
Australia. Hydro produces various types of
63
ingots which are used to produce a vast range
of products, including roofing materials, foil,
truck bodies, boats, doors, windows, commercial shop fronts, cables, tubing. Current production capacity is approx. 180,000 tpy.
Alignment, engagement and trust
According to Shane Burns, being aligned with
the customer’s goals and expectations for the
business is the first step to building a successful alliance. The alliance team at BSL is an
integrated team made up of BSL and WorleyParsons personnel. This is helpful for team
alignment, but in Burns’ opinion, this level of
alignment is just not enough. “Making sure the
people on the team are all on the same page
is critical, but you need to get right the fundamentals that come before the team is even
formed. Understanding customer needs, and
creating targets that will improve outputs to
deliver to these needs, these are important if
both parties are to be engaged, and it takes
a lot of listening, open communication and
planning,” he says.
Trust, Ian Waterman says, is a vital part of
the equation, and it can only be built over time,
with shared successes and with the learning
that comes from experience. “The whole concept of alliances can initially be daunting for
some, especially those coming from corporate
cultures where it’s normal to keep certain information close to one’s chest. Alliancing turns
that whole paradigm on its head,” he says.
While the Hydro alliance is not an integrated
team model like the one at BSL, it emphasises
transparency in information, from resource
planning to how the customer is billed down
to the last hour, and this is perhaps even more
paramount to the process of building the level
of trust needed to deliver outstanding results,
according to Waterman.
Chris Lovelock agrees that an alliance can
only work for both parties if trust is built from
the start. “There must be an atmosphere of
trust that can only occur through the appreciation of each other’s goals. In that sense, a
successful alliance is the purest example of
win/win that comes to mind,” he says.
WorleyParsons sees its expertise in alliance
building as a valuable differentiator. Thus the
teams that the company puts in place need
not only capability of high calibre in regard
to skill set, but they need to be also made up
of people who thrive on growing their interpersonal leadership skills. Being a highly competent designer or project manager no longer
depends wholly on technical skills. There has
to be a willingness to learn from others and to
be coachable, and this requires a level of hu-
64
mility and trust in others for which the stockstandard high performers of old are not always
renowned.
At BSL, the alliance operates as a one-team
culture co-led onsite by Danie Swemmer on
the BSL side and Burns as contractor lead,
so there is no hiding from results or performance. This type of openness uncovers capability, but it also uncovers any weaknesses, and
this is where the trust factor reaps dividends in
learning and support. Burns explains: “When
a weakness is highlighted, the culture of the
team is to rally around to close any gaps that
may be apparent. When the team’s interest is
focussed on providing value to the organisation, then that support is a natural position for
the team to take, and it really shows a mature
relationship which is a rewarding thing to be
a part of here.”
Continuous improvement
replacement at Tomago. The existing HTF
blend (to heat anode paste in Paste Plants 1
and 2) had become degraded and required replacement within twelve months. The degraded fluid and the associated sludge were causing
isolation valves to leak and were damaging
existing seals and pumps.
The alliance team engaged specialists from
WorleyParsons’ oil and gas division, so as to
document the existing HTF system and to
recommend the best strategy to achieve the
change-out. Working closely with Tomago, a
cross functional team was engaged to develop
a project execution plan and to seek the necessary funds to undertake the recommendations.
The existing fluid was drained from the
system and the extensive sludge build-up was
cleared from the tanks and pipe work using
newly installed hatches and drain valves. Finally, the system was completely flushed with
a flushing fluid and then refilled with the new
non-hazardous HTF.
The HTF change-out was a success with no
recordable injuries experienced throughout
the project. This risk project was completed
within an eight day shutdown and with no impact on the site’s aluminium production. “The
overall project came in under budget, and with
positive feedback from Tomago. Ready access
to global experts within WorleyParsons was a
massive advantage to the customer, and this
helped the alliance identify further opportunities to take advantage of everything our entire
company had to offer, not just within the alliance,” says Lovelock.
Similarly, Waterman says one of the great
advantages to the Hydro alliance is its ability
An example of an improvement born from the
BSL alliance is demonstrated by a large initiative (made up of quite a number of smaller initiatives) to improve how projects are delivered.
The idea was to reduce the cycle time taken
to get a potential cost saving project from an
idea to the point where it is delivering value.
In December of 2010, we set a target to reduce
cycle time to 460 days from the average 495
they were then achieving. Fast forward to today, and the current 12 month rolling average
for project cycle time stands at around 286
days, so delivering much faster returns.
Successes like these are the bonus factor
that adds value, and this success story will be
shared more
widely across
industries at
the next Leading Practices
Forum
in
March 2012 –
a knowledge
sharing crossindustry conference initiated by Transfield Worley
Services.
An example
demonstrated Members of the alliance leadership team at Boyne Smelters Ltd
recently how Back row (from left to right): Glenn Hannan (superintendent – Growth Projects), John Rann (comthe power of missioning and start-up leader CBF 4), Graeme Byrne (manager – Growth Projects), Shane Smith (area
– Reduction Services), Nathan Jones (area leader – Reduction Lines), James Roberts (area leader
the
alliance leader
– Carbon), Dave Egner (specialist – Project Asset Management)
yields results,
Front row (from left to right): Scott Polkinghorne (superintendent – Construction), Mark Lord (area
when a Heat leader – Plant Modifications and Process Support), Danie Swemmer (manager – Projects and EngineerTransfer Fluid ing), Shane Burns (alliance manager – WorleyParsons), Ben Vandenberg (function leader – Project
(HTF) needed Controls and Pre-Engineering)
SPECIAL
to tap into the Geelong centre of excellence
in aluminium technology – a resource among
many resources available as part of the global
network of WorleyParsons experts. “There
have been numerous examples over the years
where we have been able to engage experts
not normally associated with our projects at
Hydro, the most recent case being the design
of a flue wall building station. The innovative
solutions that have come, hassle-free, from
outside the alliance are seen as a great valueadd to our customer,” he says.
put appropriate change management in place
to control the situation. The customer likes to
know we are managing their budget, and that
way there are no surprises,” he says.
Another measurable sign of successful alliancing is any improvement in safety. At the
BSL alliance, the One Way to Zero Harm
culture embraced by the company permeates
everything from design to team meetings. At
the time of writing, the BSL alliance team
Advertisement
Measuring success
Swemmer and Burns lead an empowered
group aligned by a shared vision at BSL
– every project manager’s dream team. But
how exactly does a successful alliance embed
the behaviours driven by a set of shared values
and goals?
Burns is a big believer in measurement, and
he insists that it is only through commitment
to measuring performance on every level that
success can be achieved. As prerequisites he
lists having highly motivated leaders, along
with having a set of performance metrics
which are updated and discussed on a weekly
basis, more often if necessary. “We measure
very closely and openly things like cash flow,
schedule delivery, staff turnover, budget performance and safety incidents. The performance metrics are updated constantly, and they
are there in front of everyone. I can look out
of my office and see the charts on the wall on
display for everyone to see.”
Waterman uses a purpose-built Leading
Practices Control tool and he credits this as being a major factor in helping WorleyParsons’
performance to remain strong in the alliance.
The tool provides real time data related to forecasting and cost scheduling, and is valuable not
only from an individual project perspective but
also for overall portfolio management. Waterman says this visibility is a huge advantage in
identifying potential cost overruns. “The tool
allows us to flag any problem areas so we can
had achieved 2050 days injury-free including subcontractors under their control. This is
an impressive statistic considering the harsh
working environment and the nature of the
activities performed on site.
Both Swemmer and Burns are intent on
avoiding complacency, and after a spate of
near misses they have taken pro-active steps
to maintain focus on safety. They called in
Luc Herwin, sustainability manager and safety
and risk specialist with WorleyParsons. Luc
visited the site and reviewed a wide range of
safety procedures and processes. He recommended a number of changes in communications, shutdowns hazards and contractor management. Along with this suite of recommendations, Luc also suggested tracking the Near
Miss Frequency Rate, a leading indicator and
measure of best practice across industries.
buzzwords when it comes to running a successful alliance. Waterman recounts how, after
the global financial crisis, the price of aluminium dropped and the Australian dollar spiked,
which could have lead to unpleasant losses
for both customer and contractor. “We were
proactive and saw that we had to do more with
less, so we immediately moved many of our
people onto other alliances and projects within
the business, without the customer having to
ask for this. Alliancing essentially shields the
customer from having to go through redundancies when economic factors dictate a reduction in capital projects and in associated
engineering personnel,” he says.
Burns highlights that another ongoing challenge can be staff retention, and he is pleased
that in his team the turnover rates have
dropped to less than 10%. “There is a sense
of community here. Admittedly, it is a great
place to live for people with families and for
singles alike, but without job satisfaction there
is no way our turnover would be so low,” he
says. Waterman says that visitors often comment on the atmosphere at the Hydro alliance,
and they leave energised by the enthusiasm
exuding from a team fully engaged in delivering successful outcomes. Listening to Burns
and Waterman talk about the importance of
culture, it seems that successful alliancing is all
about the quality of relationships, both those
between individual colleagues, and those between customer and contractor.
Has culture then, become more important
than strategy? “I don’t know about that,” says
Burns, “but certainly building a strong culture
is part of our strategy for success. I don’t think
you can ever separate the two.”
Author
Ongoing challenges
Burns, Lovelock and Waterman all agree that
the main challenge that keeps them on their
toes is to ensure they are constantly able to
demonstrate the value of the alliance to the
customer. Flexibility and agility are not just
Stuart Clough is WorleyParsons’ industry director –
Aluminium. He has over 20 years of experience
in the aluminium industry and has been involved
in projects for Emal, Mozal, Rio Tinto Alcan Bell
Bay, Hydro Aluminium Kurri Kurri and Tomago
Aluminium. Stuart is currently based in Abu Dhabi.
Modelling cathode cooling after power shutdown
M. Dupuis, Jonquière and A. Tabereaux, Muscle Shoals
When a long power outage imposes a
shut-down and restart of electrolysis cells
at aluminium smelters, this causes irreversible and non-repairable damage to
the cathodes. Experience has shown that
this damage shortens pot life on average
by about 200 days, but the loss in pot
life varies from 100 to 400 days at different aluminium smelters. Cooling cells to
ambient temperature causes the formation of numerous and often deep cooling
cracks on the top surface of the carbon
cathode lining, both in individual cathode
blocks and in the seams between blocks.
The mechanism for the formation the
cooling cracks has not previously been
determined. Although there have been
numerous publications regarding the pre-
65
Images: GeniSim
Fig. 1: 1 metre length of transverse cathode
cooling crack
heating of cathode lining of aluminium
electrolysis cells, this work represents the
first to effectively model the cooling of
cathode linings due to a power outage. It
is also the first to report the extent and
consequence of thermal gradients formed
in the cathode lining during cooling, and
to relate these to stresses and crack formation.
Power interruptions at aluminium smelters:
During the past ten years there has been an
increase in the shutdown and restart of aluminum potlines due to long power interruptions (of more than three hours) at aluminum
smelters [1]. Aluminium companies have been
very successful in using amperage creep to increase productivity and profitability at most
existing aluminium smelters. But this increase
has come at a price, as it tends to shorten the
lifetime of transformer/rectifier systems. For
instance, the majority of long power interruptions were due to failure of the transformer/
rectifier systems, especially those at older
aluminum smelters built 20 to 40 years ago.
Harsh weather conditions, such as ice storms,
snow and high wind velocity, are also major
factors in causing long power interruptions,
and are frequent in China during the Winter.
A somewhat surprising development is that
several modern high-amperage smelters (e. g.
Fjardaal, Qatar and Dubal) have experienced
recent shutdown of potlines due to failures at
their power generation stations and/or in national grid system.
Cooling the electrolyte to below 850 °C
causes the bath to solidify and risks the shutdown of the operating cells. It requires a great
deal of effort, prior planning and experience
to survive power interruptions that last longer
than three hours. However, it is astonishing
that there are a few reported instances in
which potlines have survived power interruptions of up to eight hours.
Cathode cooling cracks: The rapid cooling
of aluminium cells from an operating electrolyte temperature ~960 °C to ambient 25 °C
due to potline shutdown generates cooling
cracks on the cathode surface; this phenomenon is observed in almost all cells in which
the solidified metal pads are removed and the
surface cleaned for inspection. The cracks are
certainly formed in the cathode block during
cooling, and not during cell operation, because
there is no bath or a yellow film of aluminium
carbide on the surfaces of the cracks as shown
in Fig. 1. The width of observed cooling cracks
is generally from 1.6 to 3 mm and may extend
the length of the cathode blocks (~300 cm).
The distances between cooling cracks vary
widely, but are typically found to occur about
two cathode blocks apart.
Fracture behaviour of carbon: The thermoelectro-mechanical behaviour of new cathode
carbon has been described as elastoplastic [2].
Carbon cathode blocks initially behave elastically, with reversible deformation as stress is
applied; however, when the stress continues to
increase, the carbon material starts to behave
in a more plastic manner, and undergoes irreversible deformation
until fracture occurs.
Micro-cracks can be
Fig. 2: Average metal pad cooling rate, from the quarter cell model
66
generated during calcining and graphitisation
of cathode carbon materials; but under compressive loading the micro-cracks tend to gradually close with volume contraction. Thereafter, when stresses become high, macrocracks are again initiated in the material and
they begin to propagate until failure occurs.
The cathode carbon is weakened as it undergoes ductile-brittle transformation during cell
operation. The cathode lining eventually becomes saturated, (more than 3%) with interstitial sodium absorbed into the carbon lattice.
This sodium causes swelling and changes the
properties of the carbon lining, making the
cathode material less ductile and more brittle.
In addition, the cathode blocks are significantly weakened by micro-cracking caused by the
diffusion of sodium into the carbon lattice.
Thermal gradients in the cathode lining:
This paper explains how rapid cooling of cathodes due to power interruption generates an
uneven temperature distribution in the cathode lining. The temperature gradient results in
a thermally induced mechanical stress which
is sufficient to cause cracking. During cooling,
the top of the cathode blocks cools faster than
the bottom, resulting in large temperature gradients. Sørlie and Øye report that “due to the
very limited elastoplastic deformation properties of carbon during rapid thermo-mechanical
strain, the accumulated stress will be released
as surface energy in the form of bottom cooling cracks” [3]. Cooling cracks weaken the
carbon lining, as some of them may fill with
aluminium upon restart; some cracks continue
to expand and link up, and so become a basis
for later pot failure.
Thermal modelling results
Cathode cooling rate: When a cell loses pow-
Fig. 3: Temperature after 24 hours of cooling, from the 3D quarter cell model
SPECIAL
er, it initially continues to dissipate the same
amount of heat. But there is no more heat input, so the cell starts to cool down. The average
cooling rate depends on the intensity of the
heat loss, which itself depends on the operating conditions prior to the power shutdown,
and on the cell’s thermal mass. Modern high
amperage cells are typically designed and operated to maximise production, so they work
at very high current density and correspondingly high cell superheat, with thin side ledge
thickness and high side wall heat flux.
As the authors demonstrated in [4], it is
possible to model cathode cooling. The cell
design and cell operating conditions used
in that previous study were typical of early
1990 high amperage conditions, so the resulting cooling rate was correspondingly less than
the rate recently measured [5]. Fig. 2 shows the
average metal pad cooling rate measured on
a retrofitted cell design with SiC side blocks.
This cell operated at a higher current density
and correspondingly higher superheat prior to
the shutdown. Its average cooling rate is very
similar to that shown in Fig. 10 of [5]. Fig. 3
presents the cell temperature distribution after
24 hours of cooling, calculated from the full
quarter cell model, while Fig. 4 presents only
the cathode panel temperature section. It can
be seen that the temperature on the cathode
panel surface is lower than that directly below
at the collector bar level.
Cathode cooling cracks: This cell cooling
is sufficient to cause cooling cracks on the
cathode surface. The cracks run mostly in the
transverse direction of the cell, like the one
shown in figure 1. A longitudinal tension stress
of at least 8 MPa is needed to generate those
cracks, according to the cathode block properties presented in [6].
It was not possible to predict that level of
longitudinal tension stress in the previous study
[4]. In that model, the cathode panel was prevented from deflecting down, but it was free to
contract in both horizontal directions. By using
this limited type of displacement constraint,
the level of tension stress predicted was only
around 2 MPa, which is about four times less
than that required to generate cooling cracks.
Yet, already in that previous study, the
longitudinal tension stress was sufficient to
generate cooling cracks when the 2D thermal
stress model was solved in plain strain mode.
Fig. 6 shows the longitudinal stress component
obtained using the 2D thermal stress model in
plain strain mode, using the thermal gradient
after 24 hours, as shown in Fig. 5. Figure 5 is
itself the result of the new transient analysis
model which produces the faster cooling rate.
As in the previous study [4], the thermal gradient used for the thermal stress analysis is
the difference between the initial steady state
temperature and the temperature calculated
after 24 hours of cooling.
When assuming plain strain, the 2D model
does predict longitudinal tension stresses high
enough to cause cracking, as it did in the initial study. But those results were then considered unrealistic, as they are based on the assumption that the cathode is restrained from
shrinking longitudinally. After discussing the
issue with Morten Sørlie, the authors reconsidered the situation; according to Sørlie, the
collector bars which are anchored by the pier
substantially prevent the cathode panel from
shrinking freely in the longitudinal direction.
Fig. 7 shows the longitudinal stress component
obtained using the 3D quarter cathode panel
model. This assumes that the collector bars
prevent the vertical carbon faces in the slots
from moving longitudinally. As can be seen in
Fig. 7, this type of restraint generates enough
longitudinal tension stress to cause transversal
cracks. So it is safe to assume that as Sørlie pro-
Fig. 4: Temperature of the cathode panel after 24 hours of
cooling, from the 3D quarter cell model
Fig. 6: Longitudinal stress component in the cathode block
after 24 hours of cooling, from the 2D model
Fig. 5: Relative thermal gradient in the cathode block after
24 hours of cooling, from the 2D model
Fig. 7: Longitudinal stress component in the cathode panel
after 24 hours of cooling, from the 3D quarter cathode cell model
67
poses, collector bars do substantially present
the cathode panel from shrinking freely in the
longitudinal direction of the cell.
Looking to a cure to the cathode cooling
cracks problem: In the previous study [4], it
was suggested that since it is the metal pad that
generates the reversed vertical thermal gradient in the cathode blocks, then tapping the
metal pad as quickly as possible after the power shutdown should reduce the risk of cooling
crack formation. This conclusion assumes that
the tension stress and the corresponding cooling cracks arise because the cathode panel is
not free to bend down. Under that assumption,
reducing the intensity of the reversed vertical thermal gradient did significantly reduce
the top surface tension stress. Yet, that stress
intensity was already four times less than is
required to produce cooling cracks!
The new assumption is that the cathode
panel as a whole, but more so the top section,
wants to shrink, but that the collector bars anchor the bottom section of the cathode panel,
so preventing it from shrinking. Under those
conditions the only stress relief option left to
the cathode panel is to generate cooling cracks.
This was confirmed by model results.
In a way, the cooling cracks problem was
already identified in the previous study [4]:
the cell lining design needs to be modified so
as to avoid anchoring the collector bars in the
pier region. A third study could demonstrate
this stress reduction, assuming that there is a
structural solution to this new collector bar
design requirement. So far, such a solution is
far from obvious.
Conclusions
This paper demonstrates that mathematical
modelling can explain the cooling crack formation because the cathode panel as a whole
tries to shrink, but the collector bars prevent
this. The metal pad cools the top section of
the cathode panel faster, which compounds the
problem, but this is not the main factor.
It therefore appears that only a cell lining
design change can be expected to provide a
cure. The aim of such a cell lining design would
be to prevent the pier from rigidly anchoring
the collector bars.
References
[1] A.T. Tabereaux, ‘Electrical Power Interruptions:
An Escalating Challenge for Aluminum Smelters’,
Light Metal Age 69 (2011)1, 26-32.
[2] G. D’Amours, M. Fafard, A. Gakwaya, and A.A.
Mirchi, ‘Mechanical Behavior of Carbon Cathode:
Understanding, Modeling and Identification’, Light
Metals 2003, ed. P. N. Crepeau (TMS, Warrendale,
Pa.), 633-640.
[3] M. Sørlie and H.A. Øye, ‘Cathodes in Aluminium Electrolysis,’ Aluminium-Verlag Marketing &
Kommunikation GmbH, Düsseldorf, Germany, 3rd
Edition 2010, 662 pp.
[4] M. Dupuis and A. Tabereaux, ‘Modeling Cathode Cooling due to Power Interruption’, Light Metals
2012, (TMS, Warrendale, Pa) to be published.
[5] K. F. Lalonde, W. Cotton and R. M. Beeler, ‘Rate
of Metal Cooling in Aluminum Reduction Cell removed from Line Current – Method and Model’,
Light Metals 2006, ed. T. J. Galloway (TMS, Warrendale, Pa.), 291-295.
[6] J. Hop, A. Store, T. Foosnaes and H.A. Øye,
‘Chemical and Physical Changes of Cathode Carbon by Aluminium Electrolysis’, VII International
Conference on Molten Slags Fluxes and Salts, The
South African Institute of Mining and Metallurgy,
(2004), 775-781.
Authors
Dr. Marc Dupuis is a consultant specialised in the
applications of mathematical modelling for the
aluminium industry since 1994, the year when he
founded his own consulting company GeniSim Inc.
(www.genisim.com). Before that, he graduated with
a Ph.D. in chemical engineering from Laval University in Quebec City in 1984, and then worked ten
years as a research engineer for Alcan International.
His main research interests are the development of
mathematical models of the Hall-Héroult cell, dealing with the thermo-electric, thermo-mechanic,
electro-magnetic and hydrodynamic aspects of the
problem. He was also involved in the design of experimental high amperage cells and in the retrofit of
many existing cell technologies.
Dr. Alton Tabereaux is a technical consultant in
resolving issues and improving productivity at aluminum smelters since 2007. He graduated with a
PhD in Chemistry from the University of Alabama
in 1971 and then worked for 33 years as a manager
of research and process technology for both Reynolds and Alcoa Primary Metals. He was Recipient
of JOM Best Technical Paper Award in 1994 and
2000, editor of Light Metals in 2004 and received
TMS Light Metals Distinguished Service Award in
2007. He is a lecturer at the annual International
Course on Process Metallurgy of Aluminium held in
Trondheim, Norway, and is an instructor at annual
TMS Industrial Aluminum Electrolysis Courses. He
has published over 65 technical papers and obtained
17 US patents in advances in the aluminium electrolysis process.
Aumund cooling conveyor for hot bath material
Aumund supplies equipment for handling
raw materials in the cement, iron, steel
and primary aluminium industries. In
these industries, the handling of hot and
abrasive bulk material needs custombuilt machinery to meet each customer’s
specific requirements. The company has
designed a cooling conveyor for the primary aluminium industry which provides
full control of the cooling process for hot
bath material.
More than other materials, hot and abrasive
bulk material is technologically most demanding to handle, especially when extremely hot.
For this reason Aumund found its way into
the famous Guinness Book of Records when
68
it’s Metallurgy division
installed the longest
bucket apron conveyor
for 800 °C Hot Compacted Iron (HCI).
The company has
designed a cooling conveyor for the primary
aluminium
industry
which provides full
control of the cooling
process for hot bath
material. This hot bath
material is charged
from the pots at 800 to
900 °C into a hot bath
crusher (SMV brand)
Images: Aumund
C. Niedzwiedz, Aumund Fördertechnik
Fig. 1: Aumund cooling principle
SPECIAL
Fig. 2: Example of fluoride emissions per minute
from hot bath material
and is then fed onto the cooling conveyor.
Subsequently, the hot bath material is cooled
down to between 300 and 100 °C, supported
by the downstream equipment. Thanks to a
specially designed hood on the Aumund cooling conveyor, the HF-gases emitting throughout the cooling can be collected and fed into
the existing dry scrubbing system.
The cooling conveyors are operating successfully today in several smelters throughout
Europe. The flagship installation, the largest
aluminium cooling conveyor, is being operated
by Emirates Aluminium (Emal).
Aumund has a history of providing custom-built conveying equipment. For nearly
90 years now, conveyor technology of the
highest standard has been designed and built
in Rheinberg, Germany, and supplied to the
bulk handling business. Reliable, top quality products have established an outstanding
reputation for themselves. The professional
approach to customers’ individual challenges,
and the efficiency of the solutions provided,
are well acknowledged by the market. Some
12,000 references in over 100 countries, and
spanning a wide range of industries, bear witness to that.
Responsibility for equipment for the nonferrous industry sector, and particularly for
primary aluminium production, is located in
Aumund’s Metallurgy division. Benefiting
from research, patents and long-term experience in the mining and steel sector, this equipment plays an important role in the aluminium
industry today. The products have been constantly matched to the technical progress in the
industry. Scope of supply includes bauxite and
alumina handling both in refineries and primary aluminium smelters, as well as conveying
and cooling of cryolite (hot bath material).
Currently the company is developing a
cooling system for dross in the primary and
secondary aluminium industry, where the
company has applied for a patent. Cooling is
performed under inert atmosphere on a special cooling conveyor.
The defined cooling of cryolite was jointly
invented in 1995 when SØR Norge Alumin-
ium came up with a specific enquiry. Based
on a problem Søral had in their Norwegian
plant, Aumund, in conjunction with Søral’s
engineering department manager and a Norwegian crusher expert, designed a new kind
of conveyor to handle 850 °C hot bath material. The first step was a general analysis of
the problem. An important aspect resulted directly from the production method: using the
prebake technology, when anode butts are
removed they take with them a substantial
quantity of hot bath material. Until then, the
fluoride-rich material was collected in containers and put to one side to cool on its own. The
inherent problem was that owing to the large
but variable amount of hot bath material in
the containers, no prediction could be made
as to when the bath lumps would reliably have
cooled down to 100 °C or less. Even after 24
hours of cooling time, the bath material could
still be too hot. Since the material must not
be hotter than 100 °C before further processing, the cooling time is an important factor in
efficient production. In addition, throughout
this ‘natural’ cooling of the cryolite, the emerging fluoride gas escaped uncontrolled into the
building. Applying forced convection to the
containers did not have the desired success.
When starting to develop a specific Aumund
solution, the aim was to achieve a reliable final
temperature of approx. 100 °C and an equally
reliable duration of no longer than 12 hours in
order to attain that goal. Prior to the cooling
process, a specially designed crusher from the
Norwegian company SMV processes the hot
bath material and crushes it down to a lump
size of about 200 mm. Below the crusher, the
Aumund cooling conveyor receives the still
red hot material. With a variable speed of
between 0.15 m/min and 0.5 m/min the conveyor functions like a moveable storage and
is able to adapt to the discontinuous operation
of a smelting plant. In Norway the hot material
needed a cooling conveyor featuring a 1,400
mm belt width and a length of 95 m. After that
the about now 80 °C warm bath material was
ready for further processing.
In 2005 measurements proved that HF-gas
evaporates into the environment at temperatures higher than 400 °C thus endangering employees’ health in the pot-room. The Aumund
solution includes a suction device that extracts
air already at the point where the 850 °C hot
bath material is fed into the crusher. From here
the HF-gas is fed into the existing dry scrubbing system. As the cooling progresses, the
emissions decrease and finally become negligible at a material temperature lower than
400 °C.
The cooling conveyor is covered by a hood
Fig. 3: Covered conveyor at Trimet Aluminium in
Essen, Germany, connected to a dry scrubbing
system
and connected to the existing dry scrubbing
system through suction points.
Measurements show that the suction system on average absorbs approximately 60 g/t
of bath emissions during a 3-shift operation.
When the first conveyor was being developed 2.1 t/h had to be cooled. Today the challenge has grown significantly. Today Aumund
builds cooling conveyors which can handle up
to 34 t/h. A conventional design for cooling
capacities higher than 40 t/h would not make
economic sense. The investment in infrastructure, civil work, etc. would be too great, if one
includes all costs applicable to conventional
technology, these being far more expensive
than the proposed technology. Comparing
only single subranges is not realistic, as the
technical solution is highly complex. A serious comparison must include all stages, aspects
and costs of alternative solutions, such as indicated below for cooling in skips.
Based on these requirements, Aumund
started investigations at a primary smelter
in 2006. In Slovakia the Slovalco plant had
already been operating the Aumund cooling
conveyor since 2002. They gave permission to
install a new conveyor section equipped with a
data logger and six thermocouples.
The data taken during normal operation of
the primary aluminium smelter gave Aumund
valuable results to use as a basis for new thermodynamic calculation software. This software (Fig. 4) has replaced the old conventional
method of designing cooling conveyors, and it
is based on parameters such as material layer
69
in conveyor length or airflow capacities in accordance with our customers’ references.
The main purpose of this software is to reduce costs in infrastructure, such as avoiding
the need to build bath skip storage for the period when baths are cooling prior to crushing.
Skips for cooled baths are no longer necessary. This also avoids other operational costs,
such as duplicate handling of skips, associated
vehicles and their operators. The defined cooling of bath material removes nearly all of the
fluoride gas by controlled suction. This draFig. 4: Conveyor section equipped with heat
matically enhances clean bath handling, health
protection box for data logger inside
and safety conditions in the pot-room.
The Aumund cooling conveyor for hot bath
depth, airflow above the conveyor, number material can be designed with pan widths of
of suction points, conveyor width, conveyor up to 2,400 mm and lengths of up to 200 m.
speed and lump size of the bath material. An Side-plate height depends on the material layadditional option is to incorporate restrictions er depth. The cryolite can be cooled down from
850 °C to temperatures
which allow safe operation of downstream
equipment.
The cooling capacity of cooling conveyors
supplied has increased
rapidly over the last
few years (Fig. 6). In
April 2009, the company supplied a cooling conveyor for hot
bath material (Model:
Aumund
KZB-K
2400/250/6) with a
centre distance of apFig. 5: Cooling curves for different thicknesses of bath material
prox. 153 m for Emal.
This cooling conveyor
is the largest and longest conveyor of its type
ever built; its capacity
for this application is
34 t/h.
With rising aluminium capacities, smelters need higher cryolite cooling capacity.
Fig. 6: Evolution of cooling capacity: average capacity of new installations
But still, in most plants
space is restricted. To
deal with that challenge Aumund has developed a new cooling
technology with a cooling tower that combines the advantages
of increased cooling
capacity with a smaller
footprint. It consists
of several modules of
the well-known deepdrawn pan conveyors
Fig. 7: Aumund cooling tower flowsheet
70
arranged not one after the other, but on top
of each other. They are specifically designed
for efficient cooling. The number of modules
combined in the tower depends on the capacity needed and on the outlet temperature required. As the air around each of the installed
pan conveyors can be exhausted separately,
cooling is a lot more efficient than with the
long cooling conveyor version. In addition,
several material transfers expose the hotter,
interior layers so increase cooling efficiency.
All in all, the Aumund cooling tower has a
capacity of more than 40 t/h.
Feeding is possible with a lifting system for
bins or with Aumund pan conveyors (KZB).
Employing a bucket elevator is not practicable
because mechanical wear due to the grain size
and the high temperature of the bath material would involve a great deal of maintenance
work.
Maintenance requirements are modest
thanks to utilisation of Aumund’s standard
conveyor technology. The tower is, however,
equipped with maintenance doors to allow access to the relevant points in case of emergency. A walkway surrounds the cooling tower,
so most of the maintenance and control duties
can be performed without further technical
support. A hood encloses most areas of the
tower, both enhancing a long service life and
protecting the steelwork.
The Aumund cooling tower needs less than
75% of the space that a conventional cooling
conveyor would require. A quite common dimension of this new equipment is 35 m long,
10 m high and 7 m wide. It in fact combines
both higher cooling capacity and lower footprint. Plus, the cooling tower runs completely
automatically, and so can be integrated into
the plants’ automation systems.
Conclusion
Installing modified metallic pan conveyors for
the cooling of hot bath material significantly
improves the health and safety environment
in pot-rooms. It combines clean bath handling
with defined cooling of the bath material, and
it removes the toxic fluoride gas by controlled suction. Reduced operating and investment
cost have contributed decisively to the success
of this product.
Author
Christian Niedzwiedz is project manager in the metallurgy division at Aumund Fördertechnik, based
in Rheinberg, Germany. Contact: Niedzwiedz@
aumund.de
SPECIAL
GAP Engineering
A new global supplier of aluminium casting technologies
Images: GAP
C. Briguet, J. Valloton and M. Bolliger, Sierre
Fig. 1: Vertical DC casting unit for rolling slabs, with metal level control in
the mould (new plant)
The continually increasing requirements for
productivity and quality of foundry products
require consideration in the design concept
of the whole plant. This applies in particular
to the choice of casting technology, to the
mechanical design of the installation and to
choosing suitable process automation (especially with regard to quality and product traceability). Process support during commissioning as well as possible later support in recipe
development and optimisation are other important factors which contribute to an optimal
technology transfer.
This applies to new installations as well as
Fig. 3: DC continuous casting unit for rolling slabs
and for extrusion ingot
Fig. 2: Vertical DC casting unit for rolling slabs, with metal level control in
the mould (retroffiting)
to retrofitting of existing plants. To satisfy all installing new plant as well as for modernising
of these requirements it is a great advantage existing plant. The competence in the area of
to obtain the entire system from one supplier. aluminum is mainly concentrated on:
Worldwide, there are not many suppliers who • casting machines
can on the one hand offer their own casting • extrusion lines
technologies, but also are willing to include • milling centres for thick plates
the casting technologies from competitors • sawing centres
when designing new plant or upgrading exist- • thermal processes (quenching,
heat treatment)
ing plant.
For all these reasons, GAP (Global Auto- • induction furnaces.
mation Process) Engineering SA decided, as In the field of casting techniques, engineers of
from 1 Jan. 2011, to take over the activities GAP already contributed decisively in Alusuof the company Rihs Engineering AG, and at isse/Alcan to the development of Valcast 5,
the same time to reinforce its capacity in cast- which in the meantime has been developed
ing technologies. GAP Engineering and Rihs to the present GAPcast [2, 3], one of today’s
Engineering have each been successfully ac- leading casting automation systems.
Technological know-how of the various
tive for many years in their traditional areas.
For about 30 years Rihs Engineering was casting processes is important in realising the
an exclusive engineering supplier of foun- projects. To consolidate this know-how, GAP
dry equipment for the Technology Centre Engineering has contractually engaged several
Alusuisse / Alcan
in
Chippis, which resold
this equipment within
the Alusuisse group
and also to third parties. GAP Engineering
was founded in 2000
by former Alusuisse
employees with more
than 15-years experience.
The activities of
GAP Engineering concern mainly the execution of global automation solutions for Fig. 4: EMC continuous casting unit for rolling slabs (new plant)
71
Fig. 5: EMC continuous casting unit for rolling slabs (retrofitting)
process engineers with many years of professional experience in these processes. The task
of these process experts is also to familiarise the employees of GAP Engineering with
these different technologies and to train the
customers’ employees when commissioning
the equipment.
In the previous structure before the merger,
both companies have worked closely together, but as independent suppliers, to realise a
large number of casting systems. These casting
processes were for billet and slab casting (for
hot-top or for electromagnetic casting, casting
with floats or with liquid level regulation in
the mould) as well as for strip casting.
Fig. 1 shows a casting unit using Wagstaff
moulds to produce five rolling slabs. This
unit has an automatic level regulation in the
moulds. The moulds can be rolled aside on a
car, and the other casting equipment is also arranged to move out of the way, which greatly
helps in the handling of ingots and equipment.
The plant shown in Fig. 2 can cast 2, 3 or 4
slabs at a time. This plant is also equipped with
automatic metal level control in the mould and
with a mobile mould car.
According to the product mix in a foundry, the continuous casting unit can also be
installed so as to operate in different modes.
Fig. 3 shows a DC continuous casting unit
which, for instance, can cast extrusion ingots
with float regulation or alternatively can cast
rolling slabs using automatic metal level control in the mould.
EMC casting (Electromagnetic Casting: a
magnetic field prevents mould contact) also
belongs to both companies’ expertise [1]. EMC
is mainly used for alloys which tend strongly to
hot cracking (2xxx, 7xxx) or to cold cracking
(3xxx, 5xxx), and where the products must
meet high quality requirements for surface
and for internal structure. Fig. 4 shows a 6-
72
Fig. 6: Vertical EMC continuous casting unit for extrusion ingot
fold EMC continuous casting unit which can
also employ Wagstaff LHC moulds. This is a
new casting unit. Fig. 5 shows an originally DC
casting unit which has been modified for EMC
casting.
The use of EMC for very wide, oval extrusion billets allows a much higher extrusion
speed, and hence productivity, thanks to the
very thin surface segregation zone. In order
to reach the same productivity, conventionally cast ingots generally need to be scalped
(milled) on both flat sides to remove the much
thicker segregation zone. Fig. 6 shows such a
6-fold casting unit with mobile moulds on a
casting car.
Together with a hot-top process, the project
can in principle combine any of the casting
units currently available on the market.
To modernise existing roll caster or rotary
caster units, customers can of course also call
on the know-how of GAP Engineering (Fig. 7).
Today, worldwide (in North America,
China, Belgium, Germany, France, Greece,
Iceland, Austria, Switzerland and Czech Republic) about 50 such different casting units
are successfully in operation. By extending this
range of offers, and in particular its technological know-how, GAP Engineering is now in
a position to do technical work on the most
diverse casting equipment, from the simplest
Fig. 7: Rotary strip casting unit
to the most complicated.
Thus the process range includes practically
all continuous casting processes which are now
available on the market, whether for new plant
or for modernising existing plant. This establishes a firm basis for a very flexible and competent treatment of the most diverse customer
requirements.
References
[1] M. Bolliger and B.F. Prillhofer: EMC confirms its
quality lead, Increase in capacity at Amag casting in
Ranshofen, ALUMINIUM 86 (2010) 7-8, p. 44-47
[2] C. Briguet and M. Bolliger: GAPCast control
makes aluminium vertical casting safer and more
efficient, ALUMINIUM 87 (2011) 1-2, p. 56-58
[3] GAP Engineering SA: Description of GAPCast
automation, 2010
Authors
Christian Briguet is co-owner of GAP Engineering SA, a SME company located in Switzerland,
in the heart of the Swiss Alps. He had worked for
Alusuisse / Alcan Technology & Management Ltd
in Chippis / Switzerland from 1996 to 2001 and participated in Valcast 5 development. After the closing
of Alcan Technology & Management in 2004, he
contributed to the development of the new ‘GAPCast’ automation concept and to its deployment.
He designed and installed more than 30 casting
machines (Valcast 5 then ‘GAPCast’) all around
Europe. Contact: [email protected]
Julien Valloton, mechanical engineer, is the
general manager of Rihs Engineering AG. He is in
charge for the transfer, maintaining and optimisation of mechanical engineering and process knowhow in casting technology at GAP Engineering.
Martin Bolliger, a casting technology consultant,
was formerly assistant vice-president of Alusuisse/
Alcan Technology & Management Ltd in Switzerland. He has designed and installed EMC [1] and
conventional casting machines at many different
sites and is an independent expert in this area.
TECHNOLOGY
Verbesserungen der Dickentoleranzen an
einem zweigerüstigen Aluminium-Kaltwalzwerk
L. Witham, Alunorf; A. Brickwedde, ABB Automation
Improvement of thickness tolerances
for a two-stand aluminium cold rolling mill
L. Witham, Alunorf; A. Brickwedde, ABB Automation
The implementation of additional control
loops to compensate backup roll eccentricity and harmonic hardness variation
allows a significant improvement in strip
thickness performance. These measures
were successfully implemented as an
automation extension to an existing twostand aluminium cold rolling mill at Aluminium Norf GmbH in Germany.
An essential quality characteristic in the cold
rolling sector is the minimum thickness deviation that can be achieved at final gauge, i. e.
from the finishing pass. However, the need
to maximise productivity requires that tight
thickness tolerances have to be achieved even
under sub-optimal mill and entry strip condi-
tions. To meet this requirement there is a need
for improved, intelligent control concepts.
The analysis of a two-stand aluminium cold
rolling mill has shown that process-related
disturbances such as backup roll eccentricities
and harmonic strip hardness variations can
make it difficult to meet the target thickness
tolerance. Backup roll eccentricity is not only
the result of grinding and roll assembly tolerances, but can also be thermally induced during
work roll changes and other stoppages. Strip
hardness variation is less well understood, but
an earlier ABB study has shown that for thin
strip, cyclic hardness variations as small as 2%
in the incoming strip can have a large impact
on thickness deviation. Such hardness variations can easily occur in aluminium alloys as
Regelungskonzept mit Erweiterung um die Funktionalitäten für Rec und Hdc (gelb)
Control loops for eccentricity compensation (Rec) and hardness compensation (Hdc)
Images: ABB
Abb. / Fig. 1
Dickenabweichung
Bandzug
Walzspaltposition
Moment
Drehzahl
V
dv/dt
En
Ex
Afc
Geschwindigkeit
Beschleunigung
Eingang
Ausgang
Planheitsregelung
dh
Thickness deviation
FT
Tension
S
Roll gap position
Tq
Torque
n
Speed
Tenff Tension feed forward
v
dv/dt
En
Ex
Afc
Velocity
Acceleration
Entry
Exit
Automatic
flatness control
dh
FT
s
Tq
n
Coi
Haspelregelung
Mdr
Walzmotorregelung
Rol Umlenkrollenregelung
Dfc
Zugregelung
Zugregelung über
ItcV
Geschwindigkeit
Coi
Coiler control
Mdr
Mill drive control
Rol
Roll control
Dfc
Tension Control
tcV
Tension control
via velocity
Rgc
Thfb
Thff
Rbc
Rsc
Walzspaltregelung
Monitorregelung
Dickenvorsteuerung
Biegeregelung
Verschieberegelung
Rgc
Roll gap control
Thfb
Thickness feedback
Thff Thickness feed forward
Rbc
Roll bending control
Rsc
Roll shift control
Rec Roll eccentricity control
Der Einsatz von zusätzlichen regelungstechnischen Maßnahmen wie Stützwalzen-Exzentrizitätskompensation und
die Kompensation von drehzahlharmonischen Härteschwankungen erlauben
eine signifikant verbesserte Banddickenqualität. Erfolgreich umgesetzt wurden
diese Maßnahmen als technologische
Erweiterung an einem vorhandenen zweigerüstigen Aluminium-Kalzwalzgerüst bei
der Aluminium Norf GmbH.
Ein wesentliches Qualitätsmerkmal beim Kaltwalzen ist die nach dem letzten Stich err
zielbare Dickentoleranz. Die Nachfrage und
Notwendigkeit der Einhaltung von engen Dickentoleranzen ist vor allem auch bei nichtoptimalen Anlagen- und Vorbandzuständen zu
erreichen. Um diesen Anforderungen gerecht
werden zu können, besteht der Bedarf nach
verbesserten, optimierten und intelligenten
Regelkonzepten.
Analysen an einem zweigerüstigen Aluminium-Kaltwalzgerüst haben gezeigt, dass
durch prozessbedingte Störungen wie Stützwalzen-Exzentrizitäten und harmonische
Härteschwankungen die Einhaltung der geforderten Dickentoleranzen problematisch
sein kann. Stützwalzen-Exzentrizitäten können z.B. durch thermische Effekte verursacht
sein. Eine frühere ABB-Studie hat gezeigt,
dass bei dünnen Bändern Härteschwankungen
von nur zwei Prozent für eine enge Dickentoleranz problematisch sein können. Solche
Härteschwankungen können bei Aluminiumlegierungen durch ungleichmäßige Abkühlung
leicht entstehen. Dabei ist die harmonische
Härteschwankung synchron mit der Drehzahl
des Bundes am Abwickler, und die Frequenz
ändert sich bzw. wächst stetig auch bei konstanter Walzgeschwindigkeit, bedingt durch die
Abhängigkeit der Drehzahl des Abwicklers
von dem sich ändernden Bunddurchmesser.
Die Besonderheit des gewählten Konzeptes
zur Kompensation harmonischer Störungen
besteht in einer aktiven reglerbasierten Lösung,
die sich automatisch an die sich ändernden
Randbedingungen der Anlage anpassen kann.
Während bei der Kompensation von harmonischen Stützwalzen-Exzentrizitäten auf bereits erprobte regelungstechnische Konzepte
zurückgegriffen werden konnte, wurde bei der
Kompensation von derartigen harmonischen
73
TECHNOLOGIE
a result of uneven cooling. Typically the hardness variation occurs as a soft (or hard) region
on the circumference of the coil. The variation
is thus synchronous with the rotational speed
of the decoiler and the frequency increases
steadily even at constant rolling speed, as the
decoiler speed rises with decreasing entry coil
diameter.
The key feature of the selected approach
for compensating harmonic disturbances is
the use of active controllers which automatically adapt to the changing conditions of the
system. While the use of active controllers to
compensate harmonic backup roll eccentricities is well established, applying this concept
to the compensation of harmonic hardness
variations was a step in a new direction and
presented new challenges.
Therefore it was decided to first analyse,
verify and optimise these concepts within the
framework of a simulation study before implementation on the plant.
Simulation study
Simulationslauf mit Zuschalten der
Exzentrizitätskompensation bei T = 70 s
1
Walzengeschwindigkeit [m/s] für Gerüst 1 und Gerüst 2
2
Einlaufdickenstörung basierend auf realen Messschrieben
3
Simulierte Stützwalzen-Exzentrizitätsstörung
Auslaufdicke nach dem 1. Gerüst (grün mit Kompensation)
4
5
Auslaufdicke nach dem 2. Gerüst (grün mit Kompensation)
Simulation run with activation of
Abb. / Fig. 2
eccentricity compensation at T = 70 s
1
Roll speed [m/s] of Stand 1(blue) and Stand 2 (green)
2
Entry thickness disturbance based on actual measurement data
3
Simulated backup roll eccentricity disturbance
4
Exit thickness after the 1st stand (green: with compensation after 70 s)
5
Exit thickness after the 2nd stand (green: with compensation after 70 s)
Härteschwankungen zusätzliches Neuland beschritten, denn die Härteschwankungen stellen eine besondere Herausforderung dar.
Deshalb wurde entschieden, diese Konzepte zuerst im Rahmen einer Simulationsstudie zu analysieren, zu verifizieren und zu
optimieren, bevor die Implementierung auf
der Anlage erfolgen sollte.
Simulationsstudie
Im Rahmen der Simulationsstudie sollten die
neuen Konzepte zur aktiven Kompensation
der Dickenstörungen durch Stützwalzen-Exzentrizitäten (Rec) und harmonischen Härteschwankungen (Hdc) getestet und optimiert
werden. Zu diesem Zweck wurde die zweigerüstige Anlage inklusive Ab- und Aufwickler
und Regelung modelliert und simuliert.
Die von ABB verwendete und entwickelte
Simulationsplattform in „Matlab/Simulink“
ermöglicht eine skalierbare, modulare und
dynamische Simulation von ein- und mehrr
gerüstigen Walzanlagen zur Entwicklung und
Analyse von neuen Regelverfahren. Die Anlage wird basierend auf Modulen wie Antrieb
und Antriebsstrang, Walzgerüst, Auf- und
Abwickler, Bandmaterial, Sensorik, Störgrößen, Regelung zu einer Gesamtanlage zusam-
74
mengesetzt und gemäß den realen Anlagenparametern parametriert. Die Regelung
umfasst Antriebsregelung, Positionsregelung
(Gerüst), Zugregelung und Dickenregelung inklusive Vorsteuerungen. Bei der Nachbildung
der Sensorik für die Banddickenmessung wird
die bandgeschwindigkeitsabhängige Transportzeit berücksichtigt.
Für Auf- und Abwickler werden der variable Radius bzw. Massenträgheitsmoment,
indirekte Zugregelung, der als Mehrmassensystem nachgebildete Antriebstrang und die
Antriebsregelung simuliert. Für das Walzgerüst werden der Mehrmassen-Antriebsstrang
mit den Walzen, die Antriebsregelung und die
nichtlineare Verformung im Walzspalt nachgebildet. Die Nachbildung des Materialbandes
berücksichtigt die unterschiedlichen Materialsteifigkeiten in Abhängigkeit von Material,
Banddicke und -breite, die bandgeschwindigkeitsabhängige Transportzeit und das Tracking
der Bunde und der Schweißnaht.
Die Nachbildung von Störgrößen umfasst zum Beispiel Einlaufdickenstörungen,
Störungen durch Härteschwankungen und
Stützwalzen-Exzentrizitäten, Bundschlag von
Auf- und Abwickler oder Reibungseffekte in
den Walzgerüsten. Die Einlaufdickenstörungen werden basierend auf real an der Anla-
Within the framework of the simulation study
the new concepts for active compensation of
thickness disturbances due to backup roll eccentricities (Rec) and harmonic hardness variations (Hdc) were to be tested and optimised.
For this purpose the two-stand mill (Fig. 1) including decoiler, coiler and all relevant control
loops was modelled and simulated.
The simulation platform in ‘Matlab/
Simulink’ as used and developed by ABB
enables a scalable, modular and dynamic
simulation of single and multi-stand rolling
mills for the development and analysis of new
control concepts. The plant to be simulated
is configured on the basis of modules, such
as drive and drive train, mill stand, decoiler
and coiler, strip material, sensors, disturbances
and control loops, and is parameterised with
the actual plant parameters. The control systems consist of drive control, position control
(roll gap control), tension control and thickness control, including feed-forward control
loops. In the modelling of strip thickness
measurement the speed-dependent transport
delays are taken into consideration.
For the decoiling and coiling processes,
the variation in radius and inertia over the
strip length, the indirect tension control, the
coiler drive trains (modelled as multi-mass
and spring systems) and the drive controllers
are all included in the simulation. The mill
stand model includes the drive train with the
rolls (as a multi-mass and spring system), drive
controllers and the non-linear deformation in
the roll-bite. The simulation of the strip takes
into account the varying stiffness depending
on the material, strip thickness and width, the
strip speed-dependent transport delay and the
tracking of the coils and weld seam.
The disturbances that are simulated include
entry thickness disturbances, disturbances due
to hardness variations and backup roll eccentricities, coil bump from the decoiler and coiler
as well as friction effects in the mill stand. The
thickness disturbances are entered into the
simulation based on real data measured in
the mill. The effective control of mass flow in
Stand 1 is decisive for the strip thickness tolerance at the mill exit. For this reason backup
roll eccentricity is especially critical in Stand
1. Analyses have shown that for hardness variations, compensation in both stands may be
necessary.
For the intended investigations, in addition
to the existing control, new control loops for
eccentricity compensation (Rec) (Fig. 1) and
hardness compensation (Hdc) were implemented.
The harmonic disturbances from backup
roll eccentricities and hardness variations are
detected and separated while rolling using
a real-time analysis of the (from mass flow)
calculated strip exit thickness in each stand.
In a second step the Rec and Hdc controllers
actively suppress these disturbances by feeding correction signals to the position reference
of the mill stands.
During this process, the compensation follows the changing frequencies as functions of
both backup roll and decoiler speed. The hardness compensation presents a special challenge
since the decoiler is constantly changing its rotational speed and therefore frequency even at
constant rolling speed, due to the decreasing
coil diameter.
ge gemessenen Größen in die Simulation
eingespielt. Entscheidend für die Dickentoleranzen am Auslauf ist die Beruhigung
des Massenflusses bereits in Gerüst 1. Bei
den Analysen hatte sich gezeigt, dass die
Stützwalzen-Exzentrizität vor allem im Gerüst 1 ein Problem darstellt, während zur
Härtekompensation eine Kompensation an
beiden Gerüsten notwendig ist.
Für die geplanten Untersuchungen wurr
den daher zusätzlich zur bereits vorhandenen Regelung die neuen Regelkreise zur Exzentrizitätskompensation (Rec) (Abb. 1) und
Härtekompensation (Hdc) implementiert.
Die harmonischen Störungen von Stützwalzen-Exzentrizitäten und Härteschwankungen werden im Betrieb basierend auf
einer zeitnahen Auswertung der über die
Massenflussbeziehung erfassten Auslaufdicke nach dem jeweiligen Gerüst erfasst und
separiert, und dann im zweiten Schritt mit
Hilfe einer Regelung mit Aufschaltung der
Korrekturgrößen zur Kompensation auf die
Walzgerüstanstellung aktiv unterdrückt.
Dabei folgt die Kompensation den sich
ändernden Frequenzen als Funktion von
Walz- und Abwicklergeschwindigkeit. Insbesondere die Härtekompensation stellt hier
eine besondere Herausforderung dar, da der
Abwickler seine rotatorische Geschwindigkeit und damit Frequenz auch bei konstanter Walzgeschwindigkeit laufend mit dem
sich ändernden Bunddurchmesser ändert.
Regelkreise zur Kompensation wurden vorr
gesehen für die drei ersten Harmonischen
von Stützwalzen-Exzentrizität und Härteschwankung, wobei die erste Harmonische
typischerweise dominant ist.
Kenndaten der Anlage:
Aluminium, Al-Legierung
Material
MEHR PRÄZISION
BANDDICKE& PROFIL
laser-optisch mit
thicknessCONTROL
GESCHWINDIGKEIT
& LÄNGE
optisch mit
ASCOspeed
3-Sigma-Dickenqualitätsverbesserung nach Aktivierung der neuen Regelung mit Auswertung von Fertigstichen
(normiert auf UCL = Upper Control Limit).
Abb. / Fig. 3
3-Sigma thickness quality improvement after activation of the new control based on evaluation of coils after the finishing pass
(normalised to UCL = Upper Control Limit)
www.micro-epsilon.de
Micro-Epsilon Messtechnik
94496 Ortenburg · Tel. 0 85 42/168-0
[email protected]
TECHNOLOGIE
Stützwalzen-Exzentrizität- und Härtekompensation
Backup roll eccentricity and hardness compensation
Exzentrizitäten und
Härteschwankungen
Abb. / Fig. 4
auf dem ABB-Automatisierungssystem
800xA (Controller AC
800PEC) implementiert und an die vorr
handene ABB-Automatisierungsplattform
MP200 (Master Piece
200) aus dem Jahre
1994 angebunden.
Die notwendigen
Messwerte wie Bandgeschwindigkeiten,
Ein-/Auslaufdicken
und rotatorische Geschwindigkeiten der
Walzenantriebe und
des Abwicklers wurr
den parallel an den AC
800PEC
Controller
angebunden, um den
hohen Anforderungen
an die Zykluszeiten
mit Zugriffszeiten von
bis zu 2 ms gerecht zu
Auswertung der Dickenqualität mit und ohne
Evaluation of thickness quality with and without
werden. Die PositionsKompensation von Stützwalzen-Exzentrizitäten
compensation of backup roll eccentricities and
harmonic hardness disturbances.
und harmonischen Härtestörungen.
Sollwerte zur Kompen1
Exit speed [m/min]
1
Auslaufgeschwindigkeit [m/min]
sation werden als Zu2
2
Einlaufdickenabweichung vor Gerüst 1 [%]
Entry thickness deviation before Stand 1 [%]
3
Auslaufdickenabweichung nach Gerüst 1 [%]
3
Exit thickness deviation after Stand 1 [%]
satz-Sollwerte an die
4
Exit thickness deviation after Stand 2 [%]
4
Auslaufdickenabweichung nach Gerüst 2 [%]
vorhandene MP2005
Compensation signal Stand 1 for Rec [μm]
5
Kompensationssignal Gerüst 1 für Rec [μm]
6
Compensation signal Stand 1 for Hdc [μm]
6
Kompensationssignal Gerüst 1 für Hdc [μm]
Regelung übergeben.
7
Standard deviation exit thickness
7
Standardabweichung Auslaufdicke
after Stand 1 and 2 [%]
nach Gerüst 1 und 2 [%]
Die Messdatenauswerr
tung erfolgt über einen
Bandbreite
1.600 – 2.150 mm vorhandenen IBA durch direkte Ankopplung
Bundgewicht
29.000 kg über einen optischen Link an den Controller
Bunddurchmesser
2.700 mm AC 800PEC.
Eingangsdicke
0,7 – 3,5 mm
Keine Unterbrechung des AnlagenbeAusgangsdicke
0,2 – 1,5 mm triebs: In einem Beobachtungsbetrieb konnten
Max. Bandgeschw.
900 / 1.500 m/min die Funktionalitäten zur Exzentrizität- und
Bandzug Einlaufseite
7 – 75 kN Härtekompensation parallel zum normalen
Bandzug Auslaufseite
6 – 65 kN Betrieb überprüft und voroptimiert werden,
ohne dabei den laufenden Betrieb der Anlage
zu beeinflussen. Zusätzliche ÜberwachungsErgebnisse der Simulationsstudie
funktionen wurden vorgesehen, um zum BeiDie folgenden Schriebe demonstrieren die spiel beim Ausfall von wichtigen Messgrößen
im Rahmen der Simulationsstudie erfolgreich oder auch bei möglichen Unplausibilitäten
durchgeführten Tests zur Kompensation von in der Erfassung oder Unterdrückung der
Stützwalzen-Exzentrizitäten (Abb. 2) und harmonischen Störungen auf einen Backupharmonischen Härteschwankungen. Um die Modus umzuschalten oder gegebenenfalls die
Verbesserungen zu verdeutlichen, wurde die Kompensation abzuschalten. Wird wieder ein
Kompensation zu einem definierten Zeitpunkt normaler Betrieb erkannt, werden die Komzugeschaltet.
pensationskreise automatisch und stoßfrei
Implementierung auf der zweigerüstigen zugeschaltet.
Kaltwalzstraße: Im Anschluss an die erfolgReaktion auf Ausfall der Bandgeschwinreiche Simulationsstudie erfolgte die Imple- digkeitsmessung: Eine Besonderheit ist der
mentierung der Regelkonzepte an dem zwei- bei mehrgerüstigen Anlagen recht typische
gerüstigen Kaltwalzgerüst. Zu diesem Zweck Ausfall des Zwischengerüst-Lasers zur Bandwurde die Regelung zur Kompensation von geschwindigkeitserfassung. Da das Signal zur
76
Control loops for compensation were provided for the first three harmonics of backup roll
eccentricity and hardness variation, with the
first harmonic typically being dominant.
Plant characteristics
Material
Aluminium, Al-alloy
Strip width range
1,600 – 2,150 mm
Max. coil weight
29,000 kg
Max. coil diameter
2,700 mm
Entry thickness range
0.7 – 3.5 mm
Exit thickness range
0.2 – 1.5 mm
Max. stand speeds
900 / 1,500 m/min
Strip tension entry side
7 – 75 kN
Strip tension exit side
6 – 65 kN
Results of the simulation study
Fig. 2 shows one of the results of some of
the tests that were successfully performed
within the framework of the simulation study
for compensation of backup roll eccentricities
(Fig. 2) and harmonic hardness variations. In
order to demonstrate the improvements, the
compensation was activated after a defined
time.
Implementation on the two-stand cold rolling mill: After the successful simulation study,
the control concepts were implemented on the
two-stand cold rolling mill. For this purpose
the new controllers for compensating eccentricity and hardness variations were programmed
in the ABB Automation System 800xA (Controller AC 800PEC) and connected to the
existing ABB Automation Platform MP200
(Master Piece 200) from 1994.
The necessary process signals to be measured, such as strip speeds, entry / exit thicknesses and rotational speeds of the mill drives
and the decoiler, were connected in parallel to
the AC 800PEC controller to allow fast signal
analysis with update times down to 2 ms. The
position corrections for compensation are sent
to the existing MP200 controller and added
to the position references. Data collection is
performed by an existing IBA PDA system,
which was connected via an optical link to the
AC 800PEC Controller.
Uninterrupted mill operation: In observation mode the functions for eccentricity and
hardness compensation could be monitored
and pre-optimised in parallel to normal operation with no effect on the current operation
of the mill. Additional monitoring functions
were provided to safeguard against signal errors, e.g. to switch to a backup mode or deactivate the compensation should important
signals fail or the evaluation or suppression
of harmonic disturbances give implausible
results. If normal operation is detected again,
the compensation loops are automatically
TECHNOLOGY
blue: old control strategy
red: new control strategy
Abb. / Fig. 5
Statistische 3-Sigma-Auswertung von Fertigbunden über einen längeren Zeitraum. (normiert auf UCL = Upper Control Limit).
Statistical 3-Sigma evaluation of coils after the finishing pass over a longer time period (normalized to UCL = Upper Control Limit).
and bumplessly reactivated.
Response to failure of strip speed measurement: A special case that was considered is
the typical failure of the interstand laser strip
speed measurement due to oil or oil mist. Since
this signal is used for the calculation of the
exit thickness based on the mass flow for each
stand, a failure would lead to deactivation of
the compensation loops and this is certainly
not desired. Therefore an alternative interstand strip speed is continuously calculated
based on an online estimation of forward slip.
The compensation loops are automatically and
bumplessly switched to this estimated variable if the interstand laser speed measurement
fails. This method was first verified within the
framework of the simulation study and then implemented and successfully tested on the mill.
The individual control loops for the compensation of harmonic disturbances were put
into operation and optimised step by step, and
here again it could be shown, as in the simulation study, that thickness disturbances due to
eccentricity and hardness variations could be
successfully suppressed and that the thickness
deviation could be significantly reduced as a
result.
Results of disturbance compensation
Several measurement plots demonstrate the
improvements achieved in thickness quality
with both backup eccentricity and hardness
deviation compensation. The additional compensation loops were switched on or off while
rolling actual coils to demonstrate the improvements due to the respective control loops. Furthermore, statistical evaluations over a longer
period before and after the changeover verify the significant improvements achieved in
thickness quality (Figs 3-5).
It must be taken into account that plant- or
product-related quality problems can always
occur, that have other causes than backup roll
eccentricity or harmonic hardness variation. It
is also true that harmonic disturbances from
backup roll eccentricity or hardness variations
are not dominant or present in all coils, and
when these particular problems are not present, no reduction in thickness deviation from
the additional controllers can be obtained.
Fig. 4 shows an example of a coil with both
backup eccentricity and hardness deviation
errors. When activating the compensation for
hardness variations (HdcPosAdd Stand 1), the
lower-frequency components were suppressed
in the exit thickness signal. When activating
the eccentricity compensation (RecPosAdd
Stand 1) the higher-frequency components
were suppressed. Afterwards both compensation loops were switched off again.
Fig. 3 shows improvements in 3-Sigma
thickness quality after activation of the new
control loops for compensation of eccentricities and harmonic hardness variations. The
coils from 614 on were rolled with the additional new controllers active. The 3-Sigma
quality improvement can be clearly seen and
rises by approx. 20%.
In Fig. 5 the thickness quality of coils after the finishing pass was evaluated over a
longer period. Here again the improvements
achieved in the exit thickness quality are
clearly noticeable. The number of coils in the
< 0.8 UCL (Upper Control Limit) tolerance
band was increased from 72 to 92%.
Summary
Two new control concepts for the active suppression of typical harmonic disturbances in
single and multi-stand rolling mills were suc-
zeitnahen Erfassung / Berechnung der Auslaufdicke nach den Gerüsten über die Massenflussbeziehung verwendet wird, ist eine
ausfallbedingte Abschaltung der Kompensationskreise natürlich unerwünscht. Daher
wird über eine Online-Schätzung eine Zwischengerüst-Bandgeschwindigkeit berechnet.
Auf diese Schätzgröße werden die Kompensationskreise bei Ausfall der Lasermessgröße
automatisch und stoßfrei umgeschaltet. Auch
dieses Verfahren wurde zuerst im Rahmen der
Simulationsstudie verifiziert und dann auf der
realen Anlage implementiert und erfolgreich
getestet.
Die einzelnen Regelkreise zur Kompensation der harmonischen Störungen konnten
Schritt für Schritt in Betrieb genommen und
optimiert werden, und auch hier zeigte sich,
wie bereits in der Simulationsstudie, dass die
durch Exzentrizität und Härteschwankungen
verursachten Dickenstörungen erfolgreich
unterdrückt und damit die Dickenqualität wesentlich verbessert werden konnte.
Ergebnisse der Störgrößenkompensation
Zahlreiche Messschriebe verdeutlichen die
Verbesserungen in der Dickenqualität mit und
ohne Kompensation. Auch hier wurden zur
Veranschaulichung der Verbesserungen die
jeweiligen zusätzlichen Regelkreise zu- bzw.
abgeschaltet. Zusätzliche statistische Auswerr
tungen über einen längeren Zeitraum vor und
nach dem Umbau belegen die deutlichen Verr
besserungen in der erzielten Dickenqualität
(s. Abb. 3-5).
Dabei ist zu berücksichtigen, dass es grundsätzlich immer zu anlagen- oder produktbedingten Problemen kommen kann, die jedoch
nicht ursächlich mit der Kompensation im
Zusammenhang stehen, und dass nicht bei allen Bunden die harmonischen Störungen von
Stützwalzen-Exzentrizität oder Härteschwankungen dominant oder vorhanden sind, das
heißt dass in diesen Fällen natürlich auch keine Verbesserungen erzielt werden können.
Abb. 4 zeigt beispielhaft: Beim Zuschalten
der Kompensation der Härteschwankungen
(HdcPosAdd Stand 1) werden die niederr
frequenteren Anteile im Dickensignal unterr
drückt. Beim Zuschalten der Exzentrizitätskompensation (RecPosAdd Stand 1) werden
die höherfrequenten Anteile unterdrückt. Danach wurden beide Kompensationen wieder
abgeschaltet.
Abb. 3 zeigt die Verbesserungen in der 3Sigma-Dickenqualität nach der Zuschaltung
der neuen Regelkreise zur Kompensation
von Exzentrizitäten und harmonischen Härr
teschwankungen. Die Bunde ab 614 wurden
77
TECHNOLOGIE
cessfully implemented and tested. The concepts for backup roll eccentricity compensation and for the suppression of harmonic
hardness variations were first analysed and
verified within the framework of a simulation
study and then implemented and tested under
real plant conditions. The additional technological controllers have been in successful
operation for more than a year and statistical
evaluations have demonstrated a considerable
improvement in the exit thickness deviation
achieved.
mit zusätzlicher neuer Regelung gewalzt. Die
Verbesserungen in der 3-Sigma-Qualität sind
deutlich zu erkennen und verbessern sich um
circa 20 Prozent.
In Abb. 5 wurde eine Auswertung der
Dickenqualität von Fertigbunden über einen
längeren Zeitraum durchgeführt. Auch hier
sind die erzielten Verbesserungen in der Auslaufdickenqualität eindeutig zu erkennen. Die
Anzahl der Bunde im < 0,8 UCL-Toleranzband konnte von 72 auf 92 Prozent erhöht
werden.
getestet werden. Die Verfahren zur Stützwalzen-Exzentrizitätskompensation und zur Unterdrückung von harmonischen Härteschwankungen wurden zuerst im Rahmen einer
Simulationsstudie analysiert und verifiziert
und dann unter realen Anlagenbedingungen
implementiert und getestet. Die zusätzlichen
technologischen Regelkonzepte sind seit mehr
als einem Jahr erfolgreich im Einsatz, und die
statistischen Auswertungen demonstrieren die
deutlichen Qualitätsverbesserungen in der err
zielbaren Auslaufdicke.
Authors
Zusammenfassung
Autoren
Lawrie Witham, Aluminium Norf GmbH, Neuss.
Axel Brickwedde, ABB Automation GmbH, Mannheim. Contact: [email protected]
Zwei neue Regelkonzepte zur aktiven Unterdrückung von typischen harmonischen
Störgrößen in ein- und mehrgerüstigen Walzstraßen konnten erfolgreich umgesetzt und
Lawrie Witham, Aluminium Norf GmbH, Neuss.
Kontakt: [email protected]
Axel Brickwedde, ABB Automation GmbH, Mannheim. Kontakt: [email protected]
MicroStream-Strömungsschleifen für präzise Endbearbeitung
Zunehmende Miniaturisierung sowie
steigende Anforderungen an Oberflächen
und Funktionskanten führen dazu, dass
herkömmliche Verfahren zur Bearbeitung
der Werkteile oftmals nicht ausreichen.
Zudem steigen die Anforderungen an
die Standfestigkeit der Teile im gleichen
Maße wie die Toleranzen in der Fertigung
kleiner werden. Das „MicroStream“Strömungsschleifen der Micro Technica
Technologies GmbH aus Kornwestheim
bietet hier höchste Wiederholgenauigkeit
und Prozesssicherheit. Charakteristisch
für das Verfahren ist, dass die Herstellung
des Flächenkontaktes zwischen Werkstück und abrasiven Medium ohne ein
formübertragendes Gegenstück zustande
kommt. Damit ist das Strömungsschleifen
(auch Druckfließläppen genannt) auch
dann einsetzbar, wenn konventionelle
Verfahren durch konstruktiv bedingte
Einschränkunken scheitern.
Das Strömungsschleifen ermöglicht die Bearr
beitung von innenliegenden Oberflächen und
das Entgraten an schwer zugänglichen Stellen.
Im Vordergrund stehen dabei eine bessere
Wirtschaftlichkeit sowie Präzision und Standfestigkeit der Werkstücke.
Micro Technica Technologies hat ein spezielles, hoch viskoses Schleifmittel (Streamer)
entwickelt, das aus einem Polymer-Kunststoff
sowie Schleifkornanteilen besteht. Die Kunststoffmasse dient als flexibles Trägermaterial für
78
das Schleifmittel, das je nach Aufgabenstellung
und zu bearbeitendem Werkstoff unterschiedlich gekörnt und konzentriert sein kann. Dieser Streamer wird mit speziellem Druck in und
über das Werkstück oder Bauteil gelenkt und
beginnt dort mittels der Strömung, die durch
die Hubbewegung der Maschine entsteht, seine gezielte abrasive Tätigkeit. Das Ergebnis
ist eine äußerst feine und glatte Struktur der
Oberfläche. Das so bearbeitete, entgratete und
geschliffene Werkstück ist präzise gerundet
und nahezu frei von Reibungswiderständen
und sonstigen störenden Einflüssen.
Die MicroStream-Schleifmaschine hat zwei
Aufgaben: das Klemmen der Werkstückaufnahme sowie das Pumpen des Mediums. Der
MicroStream flow grinding for
high-precision finish machining
The result if increasing miniaturisation
and stricter demands relating to surface
quality and functional edges is that conventional workpiece machining methods
are often inadequate. Moreover, the
demand for component endurance is increasing while at the same time manufacturing tolerances are becoming smaller.
For many applications the ‘MicroStream’
flow grinding process developed by Micro
Technica Technologies, offers maximum
reproduction accuracy and process reliability. A feature of the method is that surface contact between the workpiece and
the abrasive medium takes place without
any shape-imparting counter-component.
Thus, flow grinding (also known as pressure-flow lapping) can be used even when
conventional methods are excluded because of restrictions imposed by design.
Flow grinding enables internal surfaces to be
machined and deburred in areas where access
is difficult. Its major advantages are greater
economy, workpiece precision and endurance.
Micro Technica Technologies has developed a special, high-viscosity grinding medium (known as the streamer) which consists
of a polymer plastic containing grinding grain
fractions. The plastic mass serves as a flexible
vehicle for the grinding medium, whose grain
size and concentration can be varied according
to the task concerned and the material to be
machined. The streamer is directed into and
over the workpiece or component at a controlled pressure, where by virtue of the flow produced by the stroke movement of the machine
it begins its targeted abrasive action. The result
is an exceptionally fine and smooth surface
structure. The workpiece machined, deburred
Abbildungen:
g
MicroStream
TECHNOLOGY
MicroStream-Strömungschleifen vorher und nachher
MicroStream flow grinding before and afterwards
and ground in this way is rounded off precisely
and is virtually free from frictional resistances
and other interfering effects.
The MicroStream grinding machine has to
do two things: clamp the workpiece holder and
pump the medium. The streamer is, as it were,
a ‘tool’ specially formulated for the application concerned, which circulates in a closed
circuit within the machine.
The streamer for deburring contains an
additive which envelops individual grinding
grains present in the polymer with a protective
film during laminar flow. This film prevents
detectable material removal from surfaces
contacted by the medium. At the instant of a
change in direction, however, as happens for
example at an edge, due to inertia a point of
the grinding rain breaks through the protective film and can cut material away. After the
direction change the grain is enveloped again
and the protective film acts as before.
A grinding medium with these properties
is ideal for the finish machining of high-precision components without adverse effect on
existing tolerances in the μm range. A more
frequent change of the flow direction results
in uniform radius formation on the geometry
being ground. For components requiring precise deburring of areas not easily accessible,
along with the production of an excellent surface finish, MicroStream grinding is particularly suitable.
A decisive factor for the technical development of the flow grinding process more than
Streamer ist hierbei ein speziell für den jeweiligen Anwendungsfall hergestelltes „Werkzeug“, das in einem geschlossen Kreislauf
innerhalb der Maschine zirkuliert.
Der Streamer zum Entgraten enthält einen
Zusatz, der das einzelne im Polymer befindliche Schleifkorn bei laminarer Strömung mit
einem Schutzfilm umgibt. Dieser Film verhindert auf mediumkontaktierten Flächen messbaren Werkstoffabtrag. Im Moment der Richtungsänderung, wie er beispielsweise an einer
Kante erfolgt, tritt aufgrund der Trägheit eine
Spitze des Schleifkorns aus dem Schutzfilm
aus und kann Material spanend bearbeiten.
Nach der Richtungsänderung wird das Korn
wieder umhüllt und der Schutzfilm wirkt wie
zuvor beschrieben.
Ein Schleifmedium mit diesen Eigenschaften ist hervorragend zur Endbearbeitung
hoch genauer Bauteile geeignet, ohne dass bestehende Toleranzen im μm-Bereich verletzt
werden. Ein häufiger Wechsel der Fließrichtung ergibt eine gleichmäßige Radienbildung
an der geschliffenen Geometrie. Für Bauteile,
bei denen präzises Entgraten von schwierig
zugänglichen Stellen und das gleichzeitige
Erzeugen einer hochwertigen Oberfläche gewünscht wird, ist das MicroStream-Schleifen
besonders geeignet.
Ausschlaggebend für die technologische
Entwicklung des Strömungsschleifverfahrens
vor mehr als 30 Jahren waren erhebliche
Unzulänglichkeiten bei der Bearbeitung innenliegender Werkstückgeometrien wie Bohrungsverschneidungen und Durchbrüche unter Verwendung konventioneller Fertigungsverfahren. Prinzipiell hat sich an der Aufgabenstellung bis heute nichts geändert. Aus der
verfahrensimmanenten Möglichkeit der flexiblen Anpassung an bestehende Werkstückgeometrien und deren Bearbeitung resultiert
auch das Gros an Einsatzfällen.
Die konstruktive Auslegung der zur Innenbearbeitung genutzten Vorrichtungen kann
aufgrund der Werkstückgeometrie auf den
Einbau kostenintensiver, weil stark mediumkontaktierter, querschnittsreduzierender Kerr
ne verzichten. Der kleinste Querschnitt mit
der höchsten Fließgeschwindigkeit und dem
stärksten Materialabtrag ist im Werkstück
lokalisiert. Daher unterliegt die Vorrichtung
keinem verfahrensbedingten Verschleiß. Insgesamt besteht die Vorrichtung aus weniger
Einzelteilen und ist mit geringerem Fertigungsaufwand als eine Vorrichtung zur Außenbearbeitung herzustellen und daher auch
kostengünstiger.
Bei Endbearbeitungsverfahren sehr komplizierter, dreidimensionaler Konturen ist der
Einsatz des Strömungsschleifens besonders
geeignet. Die Erzeugung solcher Konturen err
folgt auf mehrachsigen Werkzeugmaschinen
mit Oberflächenwerten, die den gestellten
Bauteilanforderungen jedoch nicht genügen
r
und nur durch das Strömungsschleifen erreicht werden können. Die zu bearbeitenden
komplizierten Konturen bedingen zwangsläufig auch einen erheblich höheren Konstruktions- und Fertigungsaufwand beim Vorrichtungsbau. Im Gegensatz zur Innenbearbeitung
muss bei der Außenbearbeitung durch die
Anordnung einer Gegenform ein Durchflussquerschnitt erst geschaffen werden.
Vielfach ist diese Vorgabe nur durch den
Einsatz von gießbaren Polyurethanen zu verr
wirklichen. Da die Gegenform verfahrensbedingt ständig dem abrasiven Mediumfluss
ausgesetzt wird, ist der zu erwartende Vorr
richtungsverschleiß erheblich höher als bei
der Innenbearbeitung. Trotz der Mehraufwendungen und offensichtlichen Nachteile im
Vergleich zur Innenbearbeitung gibt es derzeit
kein alternatives Fertigungsverfahren für derr
art kompliziert geformte Bauteile im Bereich
der Oberflächenendbearbeitung.
Die präzise Form sowie die Oberflächenstruktur der strömungsgeschliffenen Bauteile
ist einzigartig. Deshalb wird das Verfahren
vor allem in hoch technisierten Industrien mit
hohen Qualitäts- und Präzisionsansprüchen
eingesetzt. Anwendungsbeispiele findet man
heute unter anderem in der Medizintechnik
(Membranen, Ventile, Pumpen), in der Kunststoff- und Aluminiumindustrie, in der Luftund Raumfahrttechnik (Turbinen, Brennkammern, Leitschaufeln), im Werkzeug und Forr
menbau (Fittings, Formen, Matrizen).
Der Streamer ist das Werkzeug zum Strömungsschleifen. Entsprechend der Bearbeitungsaufgabe ist zwischen den Arbeitsgängen
Entgraten und / oder Polieren zu unterscheiden. Den daraus resultierenden Anforderungen wird zuallererst durch die Medienzusammensetzung und danach mittels geeigneter
Bearbeitungsparameter entsprochen.
Der wesentliche Unterschied zwischen
einem Entgrat- und einem Poliervorgang
beim Strömungsschleifen besteht in dem
lokal und geometrisch bestimmten Materialabtrag an einer Kante (Entgraten) bzw. auf
einer Fläche (Polieren), siehe Abbildungen.
Das abzutragende Materialvolumen kann in
beiden Einsatzfällen durchaus eine gleiche
Größenordnung besitzen und hat deshalb für
die Auswahl der Korngröße und der Viskosität
des Mediums keine Bedeutung. Diese Parameter werden ausschließlich durch den am oder
im Werkstück befindlichen Durchflussquerr
schnitt bestimmt.
N
79
ANWENDUNG
30 years ago was that when conventional
methods were used, there were considerably
inadequacies in the machining of internal
workpiece geometries, such as bore intersections and perforations. In principle nothing
about such jobs has changed. Most industrial
applications are related to the process-inherent possibility of flexible adaptation to, and the
machining of existing workpiece geometries.
Thanks to the workpiece geometry, in the design of the devices used for internal machining
it is not necessary to incorporate cores, which
are cost-intensive because they are severely
affected by contact with the abrasive medium and which reduce the cross-section. The
smallest cross-section with the highest flow
rate and hence the greatest removal of material is localised inside the workpiece. Thus,
the device itself is not affected by processrelated wear. Overall, the device comprises
fewer individual components, it costs less to
produce than a device for external machining,
and is therefore comparatively inexpensive.
The use of flow grinding is especially well
suited for the final machining of very complex,
three-dimensional contours. Such contours
are produced using multi-axis machine-tools,
but have surface quality values which often do
not meet specified component requirements,
which can only be achieved by flow grinding.
The machining of complex contours necessarily entails considerably greater design and
production cost and effort for the construction
of the machining device. In contrast to internal
machining, for external machining a throughflow cross-section must first be created by a
suitably positioned counter-shape.
This requirement can often only be realised
by the use of castable polyurethanes. Since by
the nature of the process the counter-shape is
constantly exposed to the flow of abrasive medium, the wear of the device can be expected
top be substantially greater than in the case
of internal machining. However, despite the
additional cost and effort and the clear disadvantages compared with internal machining,
at present there is no alternative production
method for components of such complex shape
when it comes to surface finish-machining.
The highly precise shape and surface structure of components finished by flow grinding
are unique. Accordingly, the technique is used
in high-tech industries where the demand for
quality and precision is strict. Nowadays, examples of its application exist in medical technology (membranes, valves, pimps), in the
plastics and aluminium industries for tool and
hardened metal fabrication (dies, tablet-making moulds, drawing dies, removal of eroded
layers), in aerospace technology (blisks, turbines, combustion chambers, vanes), in die
and mould fabrication (fittings, moulds, dies)
and in numerous other applications.
Streamer selection
The streamer is in effect the flow-grinding tool.
Depending on the machining task, a distinction
is made between the work steps for deburring and / or for polishing. The requirements
resulting from this are met above all by formulating the composition of the medium, and
then by the choice of suitable operating parameters.
The essential difference between a deburring and a polishing process during flow grinding consists in the local and geometry-related
determined removal of material at an edge (deburring) or over a surface (polishing), see images. In the two cases the volume of material
to be removed can be about the same, and this
is therefore not an important factor for choosing the grain size and viscosity of the medium.
These parameters are determined exclusively
by the through-flow cross-section that exists
over or in the workpiece.
N
Der neue Mercedes-Benz SL setzt auf Aluminium
Mit dem komplett neu entwickelten SL
setzt Mercedes-Benz fast vollständig
aus Aluminium und erzielt damit eine
Gewichtsersparnis von bis zu 140 Kilogramm gegenüber dem Vorgängermodell.
Konsequente Gewichtsreduzierung gehört
wie beim Ur-Modell von 1952 mit seinem
leichten Rohrrahmen auch im neuen SL zu den
herausragenden konstruktiven Merkmalen.
Dafür verwirklicht Mercedes-Benz erstmals
einen hoch steifen Vollaluminium-Rohbau in
der Großserie. Nur wenige Teile bestehen aus
anderen Materialien. Für die Abdeckung hinter dem Tank verwenden die Konstrukteure
80
The new Mercedes-Benz SL
Almost entirely made of aluminium
The completely redeveloped MercedesBenz SL has been produced almost entirely from aluminium and weighs up to
140 kilograms less than its predecessor.
Consistent weight reduction is one of the most
outstanding design features in the new SL as
was the case in its namesake, the original SL
of 1952 with its lightweight tubular frame. For
the first time Mercedes-Benz has implemented
a highly rigid all-aluminium bodyshell in a se-
ries-production model. Only very few components consist of other materials. The designers
use the even lighter magnesium for the cover
behind the tank. High-strength steel tubing is
integrated in the A-pillars for safety reasons.
The new aluminium bodyshell weighs
around 110 kilograms less than it would using the steel technology from the predecessor.
The result is perceptible and measurable, as
less weight means more dynamism and less
consumption.
Mercedes-Benz
APPLICATION
Mercedes-Benz SL 350, Edition 1
teilweise das noch leichtere Magnesium. In die
A-Säulen sind aus Sicherheitsgründen hochfeste Stahlrohre integriert.
Der neue Aluminium-Rohbau wiegt rund
110 Kilogramm weniger, als er in der StahlTechnologie des Vorgängers wiegen würde.
Das Ergebnis ist spür- und messbar, denn weniger Gewicht bedeutet mehr Dynamik und
weniger Verbrauch.
Die Alu-Struktur ist nicht nur leichter,
sondern der Stahlausführung des Vorgängers
auch hinsichtlich Steifigkeit, Sicherheit und
Schwingungsverhalten überlegen. Dafür sorgt
intelligenter Leichtbau mit für den jeweiligen
Einsatzzweck optimierten Bauteilen. So kommen unterschiedliche Aluminiumverarbeitungen zum Einsatz. Die Bauteile werden je nach
Aufgabe in Kokillenguss oder in VakuumDruckguss gefertigt, zu Strang-pressprofilen
verarbeitet oder als Aluminiumbleche mit unterschiedlichen Wandstärken eingesetzt.
Obwohl der neue SL noch komfortabler ist und mehr Assistenzsysteme als sein
Vorgänger an Bord hat und deshalb einen
Teil des durch den Alu-Rohbau erzielten
Gewichtsvorteils wieder einbüßt, zeigt die
Waage erstaunliche Zahlen: Der neue SL 500
(1.785 kg) wiegt insgesamt rund 125 Kilogramm weniger als sein Vorgänger, der
SL 350 (1.685 kg) ist sogar 140 Kilogramm
leichter. Dies ist vielen weiteren intelligenten
Detailverbesserungen zur Gewichtsreduzie-
The aluminium structure is not only lighter
but also proves superior to the predecessor’s
steel construction in terms of rigidity, safety
and comfort. This is achieved thanks to its intelligent lightweight construction with components optimised for their specific task. Thus,
diverse processes are used to make different
kinds of aluminium depending on the use the
component is to be given: the parts are made
by chill casting or vacuum die-casting, worked
into extruded aluminium profiles or into aluminium panels of different thicknesses. The
result: high rigidity, high safety levels and better vibration characteristics.
Although the new SL is even more comfortable and has more assistance systems onboard than its predecessor and therefore sacrifices some of the weight saved through the
aluminium bodyshell, the scales show some
astonishing figures: the new SL 500 (1,785 kg)
weighs some 125 kg less than its predecessor.
On balance, the SL 350 (1,685 kg) is even 140
kg lighter – all thanks to a host of other intelligent enhanced details to reduce weight, which
has also been implemented in the new SL in
addition to the aluminium bodyshell.
The SL suspension features intelligent
lightweight construction too. For instance, the
steering knuckles and spring links on the front
axle are also made out of aluminium to reduce
the unsprung masses. The same also applies to
virtually all the wheel location components on
the rear axle.
Thanks to the crash-optimised aluminium
structure, standard-fit ‘Pre-Safe’ and assistance systems on the same high level as the
S-Class, the SL is the world’s safest roadster,
Mercedes says. The rigid aluminium bodyshell
forms a sturdy passenger compartment along
with precisely defined deformation zones in
the front and rear ends. In case of the vehicle
overturning, A-pillars made out of a mix of
steel and aluminium and two roll-over bars
protect the passenger compartment.
N
rung zu verdanken, die im neuen Modell zusätzlich zum Aluminium-Rohbau verwirklicht
wurden.
Auch das Fahrwerk zeichnet sich durch
intelligenten Leichtbau aus. Zur Reduzierung
der ungefederten Massen bestehen Achsschenkel und Federlenker der Vorderachse
aus Aluminium. Das gilt auch für fast alle
Radführungsteile der Hinterachse.
Die crashoptimierte Alu-Struktur und umfassende Sicherheits-Assistenzsysteme machen den SL zum sichersten Roadster der Welt,
so Mercedes-Benz. Der steife Alu-Rohbau
bildet eine stabile Fahrgastzelle sowie präzise
definierte Deformationszonen an der Front
und am Heck. Bei einem Überschlag schützen
A-Säulen in Stahl-Alu-Materialmix und zwei
N
Überrollbügel den Passagierraum.
81
CO M PA N Y N E W S W O R L D W I D E
Hydro
Aluminium smelting industry
Acquisition of additional interest
in Alouette aluminium smelter
Marubeni Corp. and Investissement Quebec
(IQ) have reached an agreement whereby
Marubeni will acquire an additional 6.66%
ownership interest in the Alouette smelter in
Sept Îles, Canada. The acquisition price is approx. USD180m. Following the transaction,
Marubeni’s ownership interest in Alouette
will increase from 6.67 to 13.33% and its allocation of metal will correspondingly increase
from 38,000 to 76,000 tpy.
Aluminerie Alouette’s production capacity
of 575,000 tpy makes it the largest aluminium
smelter in the Americas. The plant is going to
expand its capacity up to 930,000 tpy (Phase
III project) and will start a full scale feasibility
study in 2012. Total investment for the expansion project is estimated at C$2bn. In October
2011 Hydro-Quebec had been authorised to
provide Alouette with an additional 500 MW
energy block for the Phase III project.
After this transaction, Marubeni’s worldwide volume (equity owned) of aluminium
will increase from 160,000 to nearly 200,000
tonnes. Due to continuously strong aluminium demand, especially in the rapidly growing
emerging economies such as China, India and
Brazil, Marubeni will continue to focus on further investment in aluminium and new investment in such areas as bauxite and alumina.
Rio Tinto gives green light to
additional Kitimat investment
Rio Tinto has given the green light to an additional USD2.7bn capital investment to mod-
82
ernise its aluminium
smelter in Kitimat,
British Columbia.
This new investment will allow for
completion of the
USD3.3bn project
in 2014. The modernisation project
will increase the
smelter’s
current
production capacity
by more than 48%
to approx. 420,000
tpy. First metal is
expected to come
on stream in the first
half of 2014, with
an expected ramp-up time of nine months.
The modernised smelter will be powered exclusively by wholly-owned hydropower and
will use RTA’s AP40 technology to reduce the
smelter’s CO2 emissions intensity by 50%.
Rio Tinto Alcan intends to
close Lynemouth smelter
RTA intends to close its Lynemouth aluminium smelter in Northumberland, England. The
company is also in exclusive talks on selling
the power station at the site. The smelter is
no longer a sustainable business, says RTA,
because its energy costs are increasing significantly, due largely to emerging legislation.
The management is confident that the power
station can remain in operation under new
ownership. The Lynemouth smelter employs
515 people; an additional 111 are employed
at the power station.
A power outage in the Northumberland region has left parts of RTA’s smelter in Lynemouth out of commission. Some power was
restored, allowing the Montreal-based aluminium producer to restore 123 of its 164 pots
in the smelter’s No. 1 line. But the No. 2 line
remains out of operation, a spokesman says.
Alba achieves highest
production in its history
Aluminium Bahrain (Alba), one of the
world’s largest aluminium smelters, produced
850,700 tonnes in 2011, which was the highest level ever recorded in the company’s 40year history and a substantial increase from
the 850,700 tonnes produced in 2010. Alba
CEO Laurent Schmitt said this result was accomplished without incurring any additional
expenditure. “Alba’s introduction of Six-Sigma to strengthen quality initiatives across the
organisation as well as the implementation of
lean management techniques played a substantial role in enabling Alba to achieve this
record,” he said.
Alba’s high-grade aluminium product range
includes standard and T-ingots, extrusion billets, rolling slab and molten aluminium. They
are produced to high purity standards that
exceed 99.9%.
Rusal welcomes government
commission’s decision
on the Bogoslovsk Smelter
Rusal is satisfied with the results of the Government Commission session dedicated to analysis the situation at the Bogoslovsk aluminium
smelter and to the development prospects of
the whole Urals aluminium production cluster.
The company has always emphasised that the
key condition for stable operations of aluminium smelters is energy supply tariff enabling
competitive production.
As from 1 January 2012, the Bogoslovsk
smelter will be able to enter into a direct energy supply contract with Federal Grid Company. Furthermore, Rusal will purchase the
Bogoslovsk Power Plant from IES Holding,
including rights on the contracts project for
the 230 MW Novobogoslovsk Power Plant
capacity allocation, allowing the company to
create a leading energy and metals and mining
complex in Urals Region.
The Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the primary
aluminum industry. He is also the publisher
of the standard works Alumina Refineries and
Producers of the World and Primary Aluminium
Smelters and Producers of the World. These
reference works are continually updated, and
contain useful technical and economic information on all alumina refineries and primary
aluminum smelters of the world. They are
available as loose-leaf files and / or CD-ROMs
from Beuth-Verlag GmbH in Berlin.
In turn, Rusal agreed to focus on bringing the
smelter to break-even, and over the next five
years it will upgrade the Bogoslovsk smelter’s
production facilities. The upgrade will provide production rates no lower than in 2011
levels, whilst increasing the smelter’s energy
efficiency, bringing it in-line with modern
technology.
Rusal’s alloys to be qualified by leading
European automotive companies
China will remain a net
importer of aluminium
China will be a net importer of primary aluminium over the long-term as demand grows
and production costs related to bauxite and
Rusal completes VAZ redesign
UC Rusal completed redesigning its Volkhov
aluminium smelter (VAZ) and the increase of
its production capacity as a result of the redesign. Total investment to the project amounted
to USD3m. VAZ completed the installation
of new equipment in the casthouse enabling
the smelter to start a large-scale production of
alloys and increase the casting capacity from
24,000 to 32,000 tpy. The share of alloys in
the smelter’s production will grow up to 96%.
Automotive and aerospace industries will be
main consumers of the alloys produced. The
smelter will also produce grade A356.2 aluminium alloy used in cast automotive wheel
production.
The upgraded casthouse includes a 20-
electricity prices increase. The recent capacity
shutdowns among Chinese aluminium producers underscore the high-cost structure that
burdens a significant proportion of China’s
aluminium capacity. Further production cuts
are expected after the LME aluminium price
dipped below USD2,000 per tonne for the first
time in over a year at the end of November.
China became a net importer of alumina
in 2000 and of bauxite in 2005. Net aluminium imports will grow due to the appreciating
domestic currency and further increases in
power costs. A renminbi appreciation of 10%
combined with a USD5-per-MW increase in
electricity costs would mean producers face a
USD250-per-tonne cost increase. Given that
global demand will grow 6% per year until
the end of the decade, Chinese imports will
rapidly increase.
N
Bauxite and alumina activities
with
2010.
In 2010 the
Nikolaev alumina refinery produced 1.534m
tonnes of alumina, with a
total capacity of
1.57m tonnes.
Rusal considers bauxite
production in
Sierra Leone
Hydro
Rolling slabs produced at UC Rusal’s smelters have been successfully qualified by semis
flagship Novelis. Rusal is also working on the
qualification of its products by BMW and
Volkswagen. The 5754 and 5182 alloys qualified by Novelis are used in car body production. The trial consignment of the slabs was
produced at the Bratsk aluminium smelter.
Irkutsk and Sayanogorsk smelters currently
have their cast wheel alloys going through
the qualification process. The trial consignment of AlSi7MgSr cast alloy was successfully
processed at Volkswagen. Now the German
car producer has ordered another 175-tonne
consignment for the second stage of the qualification. Two other alloys, AlSi11MgSr for
Volkswagen and AlSiCu for BMW, are also
going through the qualification step.
In 2012 Rusal plans to supply about 40%
of all alloys produced by Aluminium Division
West (about 500,000 tpy) to European markets. European countries account for more
than 15% of global aluminium consumption
with the automotive industry being responsible for the major part of this consumption. On
average, the EU transport contains 8.6% of
aluminium, the highest rate globally.
tonne holding furnace with a mixer to prepare
alloys, a conveyor with an ingot stacker for
standard ingot production, a filtration facility,
a travelling degassing and fluxing facility and
an automatic control system. The installation
was carried out by German contractor Jasper
GmbH and Russian ‘Centerenergotsvetmet’
company. The upgraded casthouse started
production at the end of 2011 just before the
smelter’s anniversary. VAZ, the oldest aluminium smelter in Russia, will mark 80 years of
operations in 2012.
Rusal’s Nikolaev refinery
reached record production level
UC Rusal’s Nikolaev alumina refinery has
delivered a record annual production level
of 1.6m tonnes of alumina during 2011. This
output was reached following a USD350m
capex programme that the refinery undertook
since 2000, resulting in significant upgrades
to the refinery’s sectors. Especially the lime
burning kiln was reconstructed with its conversion to heating gas, a fifth calcination kiln
was built and the captive power plant was reconstructed. The output increase in 2011 was
also made possible via implementation of Rusal’s production system, raising the equipment
utilisation ratio by 2.6% in 2011 compared
UC is in talks
with Sierra Leone authorities responsible for developing its
natural resources sector and bringing investment from overseas into the country.
The Russian aluminium producer is now
planning to carry out a feasibility study on future bauxite mining projects and the development of transport infrastructure. Rusal’s participation in the development of the country’s
natural resources is of significant interest to
its economic development. A memorandum
of understanding is to be developed, defining
Rusal’s future involvement in the development of Sierra Leone’s mineral resources, as
well as mutual obligations to maintain good
conditions for the company’s investments in
mining there.
N
©
83
Secondary smelting and recycling
European scrap exports
to stagnate by 2014
European scrap aluminium export volumes
will level off by 2014, increasing the availability of scrap in domestic European markets. In
future, Asian markets are expected to generate more scrap, decreasing the need for longdistance imports. From 2014 onwards, scrap
exports are expected to stagnate at around
1m tpy. Demand for aluminium will grow in
response to CO2 reduction. Europe currently
exports about 600,000 tpy of aluminium
scrap.
Globally, about 10.6m tonnes of aluminium scrap are collected each year, with 2.6m
tonnes collected in Europe. China lags behind
Europe and the USA: in 2009 there were 300
recycling plants in the USA, 273 in Europe and
just 72 in China, but Chinese domestic volumes will grow. Going forward, almost 50%
of global scrap collected will be collected in
China. But China will need to vastly improve
its scrap utilisation if it is to halt the growth
of its dependency on imported scrap. Demand
for scrap in China will double by 2020.
The resulting increased availability of scrap
in Europe may not be enough to satisfy demand, though, which will grow in response
to CO2 reduction targets, to requirements on
recycled content quotas for aluminium products, because the recycled crediting debate and
marketing campaigns aim for over 90% recycled content of products.
N
Alunorf
Aluminium semis
Embraer and Alcoa to
develop aluminium aircraft
Embraer SA and Alcoa have signed a technology sharing agreement that involves the
use of Alcoa’s aluminium alloys to support
Embraer’s development of metallic fuselage
and wings for its aircraft. Brazilian company
Embraer manufactures commercial jets of up
to 120 seats. Alcoa is a leading supplier of
aluminium sheet, plate, extrusions and forgings to the aerospace industry. In June, the
company launched a number of new aerospace
products designed to lower the weight, cost
and maintenance of new short-range aircraft,
compared to composites.
The new agreement will employ Alcoa’s
aerospace technology to help Embraer develop high-performance aluminium aircraft using
84
the newest aluminium products including aluminium-lithium alloys, advanced
design approaches
and structural technologies, and the
latest fastener and
joining technologies.
Bombardier Aerospace’s CSeries aircraft, also optimised
for the sub-150 seat
market, employs aluminium-lithium for
most of the fuselage
and carbon composite for the majority of the
wing, the empennage and the nacelles.
Coca-Cola and Novelis sign multi-year
agreement for supply of can sheet
Coca-Cola Bottlers’ Sales & Services Company (CCBSS) and Novelis have signed a multiyear agreement for the supply of aluminium
can sheet. The agreement took effect on 1
January this year. CCBSS is the Coca-Cola
entity purchasing aluminium can sheet for the
Coca-Cola System in North America.
The agreement covers the supply of aluminium can body, can end and can tab stock to
the various producers of beverage cans for
Coca-Cola in North America. The contract
continues a decades-long relationship between
the two companies and maintains Novelis’
role as the primary supplier of aluminium can
sheet to Coca-Cola in North America. Terms
of the contract were not disclosed.
Novelis completes financing
for acquisition of minority
interest in Korean subsidiary
Novelis has completed the financing for its
acquisition of the outstanding minority interest in its Korean subsidiary. The company
previously announced it would purchase
31.2% of the outstanding shares in its Korean
subsidiary for USD350m, raising its ownership to more than 99%. Novelis has borrowed
USD225m through a secured term loan, and
plans to fund the remaining purchase price
with existing liquidity sources. The new term
loan was borrowed under, and will have
the same terms as, the company’s existing
USD1.5bn term loan facility.
On 18 November, Novelis agreed with
Taihan Electric Wire and other minority
shareholders of Novelis Korea Ltd to purchase 31.2% of the outstanding shares in the
Korean corporation for USD350m, adding to
the 67.9% Novelis currently owns.
Sapa closes deal to acquire
extrusion plant in China
In September 2011 Sapa entered into an
agreement to purchase an extrusion plant 150
km North West of Shanghai. This deal was
closed on 7 December. The plant is now operated under Sapa’s management and is doing
business under the name Sapa Profiles Jiangy
in Co. Ltd. The plant has 15 presses with the
total production capacity of 60,000 tpy and
has nearly 300 employees. It is one of the
larger extrusion operations in the Yangtze River Delta region. The facility is also equipped
with casting, anodising, horizontal powder
coating, thermal break and fabrication capabilities.
Constellium Ravenswood mill ramping
up output after stretcher installed
Constellium has successfully installed a new
stretcher at its rolling mill in Ravenswood,
West Virginia, and is in the process of ramping up production. A few years ago, the old
stretcher developed some cracks due to fatigue
and other maintenance problems. The Parisbased aluminium producer had begun ramping up output at Ravenswood last summer to
build inventory ahead of the planned stretcher
outage in August. Roughly 95% of the plate
will be sold to the aerospace industry.
Previously, Century Aluminum’s Ravenswood smelter supplied Constellium with molten metal, but since Century’s smelter was
shut in February 2009 Constellium has recycled aluminium from internal production and
bought additional metal units externally.
Alcom commissions manufacturing expansion in Malaysia
Aluminium Company of Malaysia Berhad
(Alcom), a subsidiary of Novelis, announced
the commissioning of a USD5m expansion
at its Bukit Raja facility in Malaysia. The expansion consists of a tension leveller system,
designed to improve coil flatness and surface
cleanliness for overall quality and to enhance
product mix. The new equipment will provide
improvements across the existing range of aluminium sheet and heavy gauge foil products.
In addition, the investment will enable Alcom
to enter the growing market for aluminium
sheet used in consumer electronics.
Owned 59% by Novelis, Alcom is a publicly traded company located in Bukit Raja,
Selangor, Malaysia. The rolling mill uses continuous caster technology to produce a variety of rolled products, ranging from sheet and
coil to heavy-gauge foil products. The plant
is the leading supplier of rolled products in
Southeast Asia, serving the bare and coated
heat exchanger markets, along with specialty
common alloy and foil segments.
Furukawa-Sky to build
rolling mill in Thailand
Japan’s Furukawa-Sky Aluminium will build
an aluminium rolling mill in Thailand as it
looks to shift focus there from imports to Thai
production. The move comes in response to
a growing demand for locally sourced material from automakers, many of them Japanese, based in Thailand. Construction of the
factory in Rayong province is expected to start
in March 2012, with production to begin in
January 2014 at an initial annual capacity of
60,000 tpy.
The company will transfer two cold-strip
rolling machines from Japan to equip the
new unit. The machines are currently idle af-
ter discontinuation of upstream processing at
the firm’s Nikko plant. In a second phase, the
company will relocate a third rolling machine,
along with equipment for melting, forging and
hot rolling, to give the Rayong site its start-tofinish production capability. This will also increase the unit’s capacity to 100,000 tpy by late
2014, about 22% of the firm’s domestic capacity. Output from the new mill will be shipped
not only within Thailand but also to other
parts of Southeast Asia, China and India. Furukawa-Sky is targeting ¥40 billion (USD0.5bn)
in annual sales from the new mill within four
or five years.
USD17m on the modernisation of its three
foil and foil packaging plants Sayanal, Ural
Foil and Armenal, lifting foil production from
80,000 to 100,000 tpy.
Rusal’s investments in Sayanal will amount
to USD4m. The site’s production capacity will
increase from 38,000 to 42,000 tpy. This investment in Sayanal will occur by 2014, while,
in total, Rusal plans to invest USD7m in this
site. Modernisation at Ural Foil will raise the
plant’s capacity from 16,000 to 24,000 tpy at
a cost of USD7m. Capacity of the Armenal
plant is to be increased from 26,000 to 33,600
tpy, at a cost of USD6m.
Kizad signs lease agreement with Talex
Khalifa Industrial Zone Abu Dhabi (Kizad)
has announced the signing of a long-term
ground development lease agreement with the
Taweelah Extrusion Co. (Talex). Already in
May 2011, Abu Dhabi Basic Industries Corp.
(ADBIC) signed a joint-venture agreement
with Gulf Extrusions to set up the Dhs735m
(USD200m) aluminium plant Talex. The extrusion plant will be a great attraction to Kizad’s aluminium cluster, alongside Emirates
Aluminium (Emal), who is the core tenant
within this cluster.
Jindal Aluminium invests
USD160m in Karnataka plants
Rusal will spend USD17m to
increase foil output to 100,000 tpy
UC Rusal will raise its foil output by 25% by
2014, and for this the company will spend
Jindal Aluminium will invest USD160m to
set up two new aluminium manufacturing
plants near Bangalore, in the Indian state of
Karnataka. The first plant, costing USD100m,
will have a capacity of 50,000 tpy of aluminium sheet and foil and is expected to start up
in April 2012. The finished products will be
used in packaging applications, which have
significant export potential. The second plant,
expected to be operational by July 2013, will
produce powder-coated and anodised aluminium extrusions.
Jindal holds a 25% share of the Indian
aluminium extrusion market, and supplies
sectors such as construction, transport, electrical, electronics and aerospace. Its facility near
Bangalore has a capacity to produce 70,000
On the move
Orbite Aluminae has named Yves Noël vice
president of sales and marketing.
Robert O’Leary has been named a director
on Aleris’s board, replacing Ara Abrahamian,
who resigned in December.
Wise Metals Group LLC has named Andrew
Logsdon president of Wise Recycling.
Argentina’s foreign trade undersecretary Iván
Heyn, a board member of Aluar has been found
dead in a hotel in Montevideo, the capital of
Uruguay. Deputy director María José Pérez Van
Morlegan has replaced Mr Heyn in his role on
the board.
Aleris named John Zhu president of Aleris
China. Mr Zhu is responsible for directing Aleris’
Rolled Products and Extrusions operations in
China, and for developing and executing the
Aleris growth strategy across the region.
Rolled aluminum producer JW Aluminum Co.
has promoted Chester L. Roush to chief commercial officer (CCO) and has also hired Wesley
Tomaszek as chief financial officer (CFO). Roush
will oversee all sales, marketing, inside sales,
credit and logistics.
Kay Meggers has been named president,
Alcoa Global Rolled Products (GRP), succeeding Helmut Wieser, who retired at the end of
2011.
Century Aluminum Co. has named Michael
Bless as acting president and chief executive officer in the wake of Logan Kruger’s sudden exit
from the company.
Constellium has named former Alcan Inc.
and Rio Tinto Alcan veteran Richard B. Evans as
interim chairman and CEO, following the departure of chief executive officer Christel Bories.
85
tpy of aluminium products, and exports to 27
countries including the USA, UK and Brazil,
generating an annual turnover of USD160m.
Suppliers
Siemens VAI awarded two
contracts by Novelis Korea
Siemens VAI
Siemens VAI has received an order from Novelis Korea Ltd to extend its aluminium rolling mill in Ulsan. To this end, a three-stand
finishing line will be added to the plant. The
project is aimed at boosting capacity and enabling future production of high-grade aluminium strip. The first strip is already to be rolled
in July 2013.
Up to now, the hot rolling mill, which was
equipped by Siemens in 1993, operated by
Novelis in the Korean city of Ulsan consisted
of a single reversing stand with two coilers and
the necessary secondary systems. Siemens is
supplying the mechanical and electrical equipment for the new, three-stand tandem rolling
mill including a coiler and a coil handling system. In future, the existing reversing stand will
function as a roughing mill. Lightweight cropping shears will also be installed in the entry
to the finishing line.
Novelis Korea has placed a second order
with Siemens VAI to equip its new aluminium
cold rolling mill with automation and drive
systems. The plant, which is located in Yeongju,
will produce high-quality flat strip for the beverage can industry. The mill is scheduled to
start production in 2013.
Novelis is planning to construct a tandem
mill to increase the capacity of the cold aluminium rolling plant in Yeongju. Siemens
will supply all the electrical engineering and
equipment. The technological control systems with integrated gauge, strip tension and
Aluminum rod mill from Siemens VAI
86
After the expansions, the company hopes to
increase the turnover to USD400m.
N
flatness control are an important part of the
automation equipment. They are required in
order to achieve the extremely tight manufacturing tolerances demanded for the end
product. The scope of supply also includes a
Level 2 process computer which will enable
the pre-setting of the stands to be calculated
online in advance on the basis of analytical
mathematical models. All the drive systems,
which include main and ancillary motors, will
be powered by three-phase current. Siemens
will install synchronous main motors for the
stands and reels. Sinamics SM150 mediumvoltage and S120 low-voltage converters will
be used in the drives. All the systems and
components used will be taken from the integrated Siroll ALU solution platform for aluminium cold rolling mills.
Siemens VAI awarded a contract
for aluminium rod mill
Siemens VAI has received an order from the
Southwire Company, located in Carrollton,
Georgia, to supply an aluminium rod rolling
mill for end costumer Beauty Sun Holdings
Ltd. The new mill will be located in Yixing,
Jiangsu Province, China; commissioning is expected during the first quarter of 2012.
Siemens is responsible for the engineering, manufacturing and commissioning of the
rolling mill and coiler equipment for a Southwire SCR AL 7000 rolling mill. The new mill
will produce aluminium rod for the power
conductor market. The scope includes eleven
stands, which will run 15 tonnes per hour,
producing rods that are 9.5 mm, 12 mm and
15 mm in diameter. The
contract also includes
entry shear and table,
and a dual reel coiler.
The aluminium rolling
mill will complement
the company’s existing
Southwire copper rod
system, which was also
equipped by Siemens.
Beauty Sun Holdings
Ltd, part of the Heaven
and Earth Dragon group,
is located in Yixing.
Southwire has worked
together with Siemens
VAI for more than 40
years. During that time, the company built
more than 80 non-ferrous mills for Southwire
customers.
Swedish Kubal orders stub
straightening machine from VHE
Inward bending of anode stubs, generally
known as ‘toe-in’, is a well understood occurrence in all pre-bake aluminium smelters.
The difference in linear expansion of the carbon anode and the steel yoke or spider of the
anode rod at high temperatures in the reduction cell means that the yoke expands more
than the anode, bending the stubs which are
anchored in the anode block. Stubs become
bent inwards just above the iron thimble,
changing the geometry of the yoke, and stubs
can no longer be correctly located in the anode
holes during subsequent rodding. Ultimately
the stubs will no longer fit into the holes.
The machine to be supplied to Kubal (Kubikenborg Aluminium), located in Sweden,
will be designed for the 2 x 2 150 mm stub
diameter technology in use at that smelter and
will be delivered in mid-2012.
VHE of Iceland has proven solutions suitable for different reduction technologies. For
smaller diameter stubs, ambient temperature
straightening is an economical approach. For
larger stub diameters, hot straightening is often
a better solution. Stubs heated to 650 °C need
considerably less straightening force, and the
cost of an induction pre-heating unit is to a
large extent offset by savings in the heavy duty
steelwork and hydraulic systems which would
otherwise be needed.
UC Rusal approves nanocoatings
from ItN Nanovation
UC Rusal and Rusnano have announced that
Rusal’s Irkutsk Aluminium Smelter and specialists from Rusal’s Engineering and Technology Centre, have successfully tested Nanocomp Metcast, nanocoatings developed by
Rusnano’s project company ItN Nanovation
AG in Germany. Nanocomp Metcast are innovative nanocoatings tailored to casting machinery. They extend the service life of moulds
and lengthen the intervals for maintenance
of casting conveyors. As a result, the casting
process becomes more efficient at a lower
cost. Presently specialists from ItN Nanovation and Rusal study large-scale introduction
of Nanocomp Metcast at Rusal’s aluminium
smelters. Rusnano acquired an interest in ItN
Nanovation in May 2011.
N
RESEARCH
Das aec (aluminium engineering center) in Aachen – Weltweit
größtes Hochschulzentrum für Aluminiumforschung und -lehre, TTeil I
Das aec (aluminium engineering center
e.V.) zählt zu den weltweit größten Hochschulzentren für Aluminiumforschung
und -lehre. Als kompetenter Forschungsund Entwicklungspartner für industrielle
und anwendungsorientierte Forschung
bietet es einen Pool von mehr als 250
hoch qualifizierten Werkstofftechnikern
und Ingenieuren sowie eine hervorragende Infrastruktur und Ausstattung der
Institute. Durch den Einsatz modernster
Anlagen, Prozesse, Analysetechniken und
Computersoftware werden zum Beispiel
neue Legierungen und Leichtbaulösungen
möglich.
Das aec fördert die interdisziplinäre, institutsübergreifende Forschung und Entwicklung
für Aluminium und leistet so einen systematischen Knowhow-Aufbau und -Erhalt für Aluminium-Werkstoffe, -Prozesse und -Anwendungen. Durch die enge Verzahnung der Forr
schung und Entwicklung mit dem Lehrbetrieb
der RWTH bildet das aec beständig exzellente
Ingenieure für die Aluminiumindustrie und
deren Kunden aus.
Mit der Gründung des aec ist die Vision
verbunden, Aluminium als wichtigen Struktur- und Leichtbauwerkstoff in Lehre und Forr
schung an der RWTH Aachen zu fördern und
das aec zu einem weltweit führenden Center
of Excellence für die aluminiumbezogene Forr
schung und Entwicklung sowie akademische
Aus- und Weiterbildung zu entwickeln.
Die auch in der Vereinssatzung festgeschriebenen strategischen Ziele des aec sind:
die Förderung der Aus- und Weiterbildung,
die interdisziplinäre Forschung und Entwicklung und die Präsentation und Kommunikation des Werkstoffpotenzials.
Die Realisierung der Vision und die Umsetzung der strategischen Ziele setzt eine enge
strategische Partnerschaft mit der Aluminiumindustrie voraus. Das aec ist jederzeit offen für
neue Kooperationen mit allen Unternehmen
der Aluminiumbranche und den Anwenderr
industrien.
Die zehn Mitgliedsinstitute des aec geben
einen Überblick über die Erzeugung, das Urr
formen, Umformen, Fügen, Beschichten, die
Anwendung im Kraftfahrzeug- und Bausektor, das Recycling und die damit verbundenen
Technologien.
Typische Forschungsschwerpunkte der zehn
aec Mitgliedsinstitute sind im Folgenden darr
gestellt.
I.A.R. (Institut für Aufbereitung und
Recycling); Prof. T.
T Pretz, B. Wens
Forschung zum Recycling beginnt an der
Rohstoffquelle, der anthropogenen Ressourr
ce „Abfall“. Metallische Abfälle, und hier
Die aus Verbrennungsrückständen erzeugten
NE-Vorkonzentrate weisen zwar höhere Metallgehalte, sind aber hinsichtlich der automatischen Sortentrennung problematischer (z.B.
wegen mineralischer Oberflächenverschmutzungen). Ein möglichst effizienter Zugriff
auf die circa fünf Millionen Tonnen Müllverr
brennungs-Rostaschen verlangt daher eine
Kombination von klassischen physikalischen
Trennprozessen mit angepasster sensorischer
I.A.R.
aec, B. Jaroni
insbesondere Nicht-Eisen-Metalle, sind als
Ressource sowohl unter ökonomischen als
auch ökologischen Gesichtspunkten besonders interessant. Auf diese Ressourcen, die
in heterogenen Abfallgemischen (z.B. Hausmüll) enthalten sind, konzentriert sich die Forschung am I.A.R. In Deutschland werden beispielsweise etwa ein Drittel des Hausmülls
einer mechanischen und zwei Drittel einer
thermischen Behandlung unterzogen.
Die Anreicherung von NE-Metallen bei der
mechanischen Behandlung führt zu stark verr
schmutzten, nicht sortenreinen Vorkonzentraten mit Metallgehalten zwischen 30 und 60
Prozent. Um die metallischen Ressourcen aus
solchen „armen“ Vorkonzentraten heben zu
können, muss eine weitere Aufkonzentrierung
der Metalle und eine Sortentrennung durchgeführt werden. In dem von der EU-Kommission
geförderten Eco-Innovation-Vorhaben SATURN (ECO/08/239051/SI2.534294) wird
unter Verwendung moderner sensorischer
Sortiertechnik die Sortentrennung automatisiert. In unterschiedlichen Kombinationen
lassen sich Röntgen-, Nah-Infrarot- und induktive Sensoren mit Bildauswertungsverfahren
kombinieren und so Konzentrate mit enger definierten Legierungseigenschaften erzeugen.
Sortiertechnik, die in einem r³-Forschungsvorr
haben mit industrieller Beteiligung erforscht
werden.
IME (Institut für Metallurgische Prozesstechnik und Metallrecycling); Prof. B.
Friedrich; S. Gül
Im Bereich des Leichtmetallrecyclings, besonders des Aluminiumrecyclings, ist das IME
eines der führenden Forschungsinstitute Europas. Die Untersuchungen entsprechen den
Bedürfnissen der Aluminiumindustrie und
reichen von der Grundlagenforschung bis in
die Umsetzung von Up-Scale-Versuchen im
Pilotmaßstab.
Ein typisches Beispiel ist die thermische
Zersetzung organischer Bestandteile im
Mehrkammerofen beim Aluminiumrecycling.
Neben der angestrebten höheren Ausbeute
und Qualität des wertvollen Werkstoffs, kann
der Heizwert der organischen Bestandteile genutzt und der Erdgaseinsatz künftig reduziert
werden. Daher ist eines der Ziele, den Prozess
und hier insbesondere den Vorbehandlungsschritt zu optimieren um die de-coating-Effizienz zu steigern.
Ein weiterer Forschungsschwerpunkt ist
87
das Salzbadtrennverfahren, das vor allem bei
stark verunreinigten Schrotten und Aluminiumverbundwerkstoffen zum Einsatz kommt.
Im Zuge der Projektarbeit ist am IME ein
konduktiv beheizter Ofen zum Salzbadtrennverfahren als Demonstrator für die Industrie
geplant. Die Abbildung zeigt den kippbaren
Drehtrommelofen des IMEs. Das Ofenvolumen beträgt 1 m3 Aluminium. Der stufenlose
Luft-/Sauerstoffbrenner verfügt über 0,5 MW
Leistung,
Die Reduzierung des Energieverbrauchs
und Verwendung regenerativer Energie ist für
die nachhaltige Entwicklung der Industrie und
ihrer Prozesse unerlässlich. Zum Einsatz von
Biomasse zur Einsparung fossiler Brennstoffe
wird am IME aktuell die Entwicklung eines
Brenners angestrebt.
Neben der Prozessoptimierung und dem
Aufbau einer Demonstrationsanlage werden
Grundlagenuntersuchungen zur Optimierung
der Salzeigenschaften für das Aluminiumrecycling im IME durchgeführt. Hierzu werden
Eigenschaften wie Viskosität, Oberflächenspannung und Dichte ermittelt. Auch Untersuchungen zu unterschiedlichen Flussmitteln für
die Oxid/Metall-Trennung sind Gegenstand
der aktuellen Forschung.
IMM (Institut für Metallkunde und
Metallphysik); Prof. G. Gottstein, C.
Günster
Das Institut für Metallkunde und Metallphysik (IMM) befasst sich mit Forschung über
Eigenschaften metallischer Werkstoffe und
den physikalischen Mechanismen, die ihnen
zugrunde liegen. Ein zentraler Gegenstand
der Forschung ist derzeit die Nutzung des
88
3D-Kornstruktur, simuliert nach dem 3D-VertexModell [3]
von Materialeigenschaften während des Herr
stellungsprozesses, um den Kosten- und Zeitaufwand der Werkstoffentwicklung spürbar
zu verringern. Die entwickelten Modelle sind
über eine Interr
netplattform extern verfügbar.
Das Institut für Bildsame Formgebung (IBF)
der RWTH Aachen beschäftigt sich im Bereich Aluminium sowohl mit der Umformung
durch Walzen, Ringwalzen, Schmieden und
verschiedenste Blechumformverfahren als
auch mit der Prozess- und Werkstoffmodellierung von Umformprozessen und Prozessketten.
Eine aktuelle technologische Neuentwicklung stellt das Riblet-Walzen zur Herstellung
strömungsoptimierter Oberflächen in Aluminiumblechen dar. Hierzu wird die Oberfläche
des Blechwerkstoffs in einem Walzstich mit
kleinsten Rillenstrukturen versehen. Diese
sogenannten Riblets können zur Verminderung von Reibungsverlusten auf umströmten
oder in durchströmten Körpern verwendet
werden. Zum Einsatz dieser Strukturen auf
großen Oberflächen – zum Beispiel an Zügen,
Flugzeugen oder in Pipelines – müssen geeignete Strukturierungsverfahren gefunden und
optimiert werden. Das Walzen bietet die Möglichkeit, derartige funktionalen Strukturen
mit Hilfe einer negativ strukturierten Masterr
walze mit hoher Effizienz auch auf großflächige metallische Werkstücke zu übertragen.
Am Institut für Bildsame Formgebung
werden verschiedene Verfahren untersucht,
um Walzen entsprechend zu strukturieren. Hierdurch entstand beispielsweise eine
„Microwind“-Walze, die mit einem sehr dünnem Draht umwickelt wird, dessen minimaler
Durchmesser circa 90 μm beträgt. Mit dieser
Walze wurden bereits erfolgreich Riblets in
Aluminiumbleche gewalzt. Es ergibt sich ein
halbkreisförmiges Profil, das vorteilhafte
strömungstechnische Eigenschaften mit einer
vergleichsweise einfachen und kostengünstigen Fertigung verbindet.
Fortsetzung in ALUMINIUM 3/2012
[1]: M. Crumbach, Dissertation, RWTH Aachen (2005).
[2]: R. Sebald,
G.
Gottstein,
Acta Mater. 50,
(2002), 1587-98.
[3]: L. BarralesMora, Dissertation, RWTH Aachen (2008)
IBF
Kippbarer Drehtrommelofen am IME
IBF (Institut für Bildsame Formgebung);
Prof. G. Hirt, Dr. M. Bambach
metallkundlichen Verständnisses zur Berechnung von Werkstoffeigenschaften längs der
Prozesskette auf dem Computer.
So wurden am IMM unter anderem Modelle zur Simulation der plastischen Verforr
mung hinsichtlich Verfestigung (3IVM+), Verr
formungstextur (GIA) und Rekristallisation
(CORe) [1, 2], sowie des Kornwachstums mit
Hilfe von Netzwerkmethoden (3D-Vertex)
entwickelt. Die Zuverlässigkeit der Simulationsergebnisse bezüglich der Entwicklung von
Walz- und Rekristallisationstexturen im Lauf
der Prozesskette (Through-Process Modeling)
wurde durch den Vergleich mit experimentell
ermittelten Texturen bewertet und im Laufe
der Jahre durch Modifikation besagter Modelle immer weiter verbessert.
Das übergeordnete Ziel dieser Aktivitäten
ist eine zuverlässige und akkurate Vorhersage und daraus resultierend eine Optimierung
IMM
IME
RESEARCH
PAT E N T E
Patentblatt Oktober 2011
Fortsetzung aus ALUMINIUM 12/2011
Schiebefenster oder -tür mit einer Schließeinrichtung. Alcoa Aluminium Deutschland, Inc.,
58642 Iserlohn, DE. (E06B 3/44, EPA 2360343,
EP-AT: 09.02.2011, WO-AT: 09.02.2011)
Draht aus Magnesiumbasislegierung und Herstellungsverfahren dafür. Sumitomo (SEI) Steel
Wire Corp., Itama, Hyogo, JP; Sumitomo Electric Industries, Ltd., Osaka, JP. (C22C 23/02, PS
602 37 820, EP 1400605, WO 2002/099148,
AT: 16.05.2002, EP-AT: 16.05.2002, WO-AT:
16.05.2002)
Gießsystem für hohe Produktivität. MRB Aluminium LLC, Sterling Heights, Mich., US. (B22D
47/00, PS 60 2006 016 819, EP 1918045, AT:
16.11.2006, EP-AT: 16.11.2006)
Patentblatt November 2011
Verbundwerkstoffe für benetzbare Kathoden
und Verwendung derselben für die Herstellung
von Aluminium. Hydro-Quebec, Montréal, Québec H2Z 1A4, CA. (C22C 29/00, EPA 2373823,
WO 2010/037220, EP-AT: 29.09.2009, WO-AT:
29.09.2009)
Verfahren zur Herstellung eines gebrannten
Produkts auf Aluminium-Titanat-Basis. Sumitomo Chemical Company, Ltd., Tokyo 104-8260, JP.
(C04B 35/46, EPA 2368866, WO 2010/067859,
EP-AT: 11.12.2009, WO-AT: 11.12.2009)
Entkohlungsverfahren
für carbothermisch
hergestelltes Aluminium. Alcoa Inc., Pittsburgh,
PA 15212-5858, US. (C22B 5/06, EPA 2366037,
WO 2010/074845, EP-AT: 18.11.2009, WO-AT:
18.11.2009)
Eisen-Chrom-Aluminium-Legierung mit hoher
Lebensdauer und geringen Änderungen im
Warmwiderstand. Thyssen Krupp VDM GmbH,
58791 Werdohl, DE. (C22C 38/18, PS 10 2008
018 135, AT: 10.04.2008)
Verminderung des elektrischen Kontaktwiderstandes zwischen Stahlnippel und Kohlenstoffanode in der Aluminium-Schmelzflusselektrolyse. Wilkening, Siegfried, Dr.-Ing., 53347 Alfter, DE. (C25C 3/12, OS 10 2010 020 030, AT:
11.05.2010)
Widerstandspunktschweißen von Aluminium
an Aluminium und Stahl an Stahl. GM Global
Technology Operations LLC (n.d.Ges.d. Staates
Delaware), Detroit, Mich., US. (B23K 11/30, OS
10 2010 024 569, AT: 22.06.2010)
Schutzverkleidung für Holzfenster, Balkontüren und Terrassentüren in Edelstahl oder
Aluminium. Gröner, Wolfgang, 89555 Steinheim, DE. (E06B 3/30, GM 20 2011 102 081, AT:
21.06.2011)
Effektpigmente mit Aluminium- oder Aluminiumlegierungskern, Verfahren zu deren Herstellung und Verwendung derselben. Eckhart
GmbH, 90763 Fürth, DE. (C09C 1/00, OS 50
2004 003 724, EP 1685198, WO 2005/049739,
AT: 19.11.2004, EP-AT: 19.11.2004, WO-AT:
19.11.2004)
Verfahren zur Herstellung eines Bauteils aus
einem mit einem Al-Si-Überzug versehenen
Stahlprodukt und Zwischenprodukt eines solchen Verfahrens. Thyssen Krupp Steel Europe
AG, 47166 Duisburg, DE. (C23C 2/28, EP 2 240
622, WO 2009/095427, AT: 29.01.2009, EP-AT:
29.01.2009, WO-AT: 29.01.2009)
Reaktor zur Abtrennung von Aluminium aus
Mehrschichtfolienmaterialien. Korea Institute of
Industrial Technology, Cheonan, KR. (C22B 21/00,
EP 2 142 677, WO 2008/136542, AT: 02.05.2007,
EP-AT: 02.05.2007, WO-AT: 02.05.2007)
Einkapselung von Kohlenstoffmaterial in Aluminium. Dayou Smart Aluminium Co., Ltd., Seo,
Gwangju, KR; Sungkyunkwan University Foundation for Corporate Collaboration, Suwon, Kyonggi, KR. (C23C 26/00, PS 60 2008 003 181, EP
2072635, AT: 24.07.2008, EP-AT: 24.07.2008)
Überwachung der Isolierung von Interventionseinheiten, die in einem Elektrolyseraum
zur Herstellung von Aluminium durch Schmelzelektrolyse verwendet werden. E.C.L., Ronchin, FR. (C25C 3/20, EP 2 257 657, WO
009/115689, AT: 20.02.2009, EP-AT: 20.02.2009,
86)WO-AT: 20.02.2009)
Hochreine Aluminium-Sputtertargets. Praxair S.T. Technology, Inc., North Haven, Conn.,
US. (C22F 1/04, PS 602 37 911, EP 1444376,
WO 2003/042421, AT: 23.10.2002, EP-AT:
23.10.2002, WO-AT: 23.10.2002)
Abriebresistente gesinterte Aluminiumlegierung mit hoher Festigkeit und Herstellungsverfahren hierfür. Hitachi Powdered Metals Co.,
Ltd., Matsudo, Chiba, JP. (C22C 21/10, PS 10 2005
032 544, AT: 12.07.2005)
Herstellungsverfahren für Blech aus Aluminiumlegierung. Nippon Light Metal Co. Ltd., Tokio, JP; Honda Motor Co., Ltd., Tokio, JP; Novelis,
Inc., Toronto, Ontario, CA. (C22C 21/06, EP 1 771
590, WO 2006/011242, AT: 30.07.2004, EP-AT:
30.07.2004, WO-AT: 30.07.2004)
Schutzverkleidung für Holzfenster in Edelstahl
und/oder Aluminium. Gröner, Wolfgang, 89555
Steinheim, DE. (E06B 3/30, GM 20 2010 014 578,
AT: 21.10.2010)
Herstellungsverfahren für aus einer wärmebeständigen Aluminiumlegierung geformte Produkte und aus einer wärmebeständigen Aluminiumlegierung geformtes Produkt. (C22F
1/00, PS 60 2007 009 604, EP 1881084, AT:
14.06.2007, EP-AT: 14.06.2007)
Kupfer-Nickel-Aluminiumlegierung. Fossil, Inc.,
Richardson, TX 75082, US. (C22C 9/00, EPA
17.03.2011,
WO-AT:
2369024,
EP-AT:
17.03.2011)
Al-Kunststoff-Fenster mit Klebebandfixierung.
Gutmann AG, 91781 Weißenburg, DE. (E06B
3/30, PS 10 2006 054 427, AT: 16.11.2006)
Verfahren zur Herstellung eines mit guter Biegbarkeit versehenen Bleches aus Aluminiumlegierung. Novelis, Inc., Toronto, Ontario, CA.
(C22C 21/02, EP 1 392 877 , WO 2002/090609,
AT: 03.05.2002, EP-AT: 03.05.2002, WO-AT:
03.05.2002)
Modulträger aus Leichtmetall-Strangpresskomponenten für ein Fahrzeug. Volkswagen
AG, 38440 Wolfsburg, DE. (B62D 25/00, OS 10
2004 044 056, AT: 11.09.2004)
Verbindungsanordnung zweier zumindest im
Wesentlichen aus einem Leichtmetall gebildeten Bauteile. Daimler AG, 70327 Stuttgart,
DE. (F16B 5/02, OS 10 2011 013 389, AT:
09.03.2011)
Magnesiumlegierung für die Raumtemperatur
und Herstellungsverfahren dafür. Korea Institute of Industrial Technology, Choongcheongnamdo 331-825, KR.(C22C 1/06, EPA 2374906, EPAT: 24.03.2011, WO-AT: 24.03.2011)
Motorfahrzeugsitz mit Rücklehnenrahmen aus
einer monolithischen Struktur aus einer Magnesiumlegierung. Lear Corporation Italia S.r.l.,
10121 Torino, IT. (B60N 2/64, EPA 1950086, EPAT: 20.12.2007, WO-AT: 20.12.2007)
Magnesiumlegierung und Magnesiumlegierungsguss. Kabushiki Kaisha Toyota Jidoshokki, Kariya-shi Aichi 448-8671, JP. (C22C
23/02, EPA 2369025, WO 2010/055897, EP-AT:
06.11.2009,WO-AT: 06.11.2009)
Schmiedeprodukt aus Magnesiumlegierung
mit ausgezeichneter Formbarkeit und Verfahren zu dessen Herstellung. Primometal Co., Ltd.,
Anyang, KR. (C22C 23/00, PS 60 2005 024, EP
1759029, WO 2006/075814, AT: 11.03.2005,
EP-AT: 11.03.2005, WO-AT: 11.03.2005)
Magnesiumbasierte Legierung für hohe Temperaturen und Herstellungsverfahren dafür.
Korean Institute of Industrial Technology, Cheonan-si Chungcheongnam-do 331-825, KR. (C22C
1/06, EPA 2374905, EP-AT: 24.03.2011, WO-AT:
24.03.2011)
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ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige,
den Werkstoff Aluminium betreffende Patente.
Die ausführlichen Patentblätter und auch
weiterführende Informationen dazu stehen
der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen
bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
89
PAT E N T E
Herstellungsverfahren für Teile aus Magnesiumlegierungen. Matsuda, Yutaka, Takaratuka,
Hyougo, JP. (C22C 47/12, PS 600 45 156, EP
1195448, WO 2000/070114, AT: 11.05.2000,
EP-AT: 11.05.2000, WO-AT: 11.05.2000)
Aluminiumoxid bildende Legierung auf Nickelbasis. Sandvik Intellectual Property Ab, 811 81
Sandviken, SE. (C22C 19/05, EPA 2367963,
WO 2010/059105, EP-AT: 06.11.2009, WO-AT:
06.11.2009)
Stranggepresstes Rohrteil aus Aluminiumlegierung für Wärmetauscher mit natürlichem
Kühlmittel. Denso Corp., Kariya-city, Aichi-pref.,
JP; Furukawa-Sky Aluminium Corp., Tokio, JP.
(C22C 21/00, PS 60 2006 017 768, EP 1721998,
AT: 09.05.2006, EP-AT: 09.05.2006)
Fassade oder Glasdach in Brandschutzausführung mit einer aus vertikalen und horizontalen
Profilen bestehenden Tragkonstruktion. Norsk
Hydro ASA, 0240 Oslo, NO. (E04B 1/94, PS 501
11 116, EPA 1120504, AT: 20.01.2001, EP-AT:
20.01.2001)
Schließrahmen einer Schiebetür oder eines
Schiebefensters, der einen verdeckten Pfosten umfasst. Bezault SAS, Longue, FR; Norsk
Hydro ASA, Oslo, NO. (E06B 3/263, PS 60 2008
003 039, EP 1953327, AT: 30.01.2008, EP-AT:
30.01.2008)
Verfahren und Werkzeug zur Oberflächenbehandlung. KS Aluminium-Technologie GmbH,
74172 Neckarsulm, DE. (B23P 9/00, PS 10 2009
058 178, AT: 15.12.2009)
Titanaluminid-Legierungen mit guter Kriechfestigkeit. Avco Corp., Providence, R.I., US;
Howmet Corporation, Independence, Ohio, US.
(C22C 14/00, OS 694 00 848, EPA 0636701,
AT: 16.05.1994, EP-AT: 16.05.1994)
Plattierplatte und Herstellungsverfahren dafür.
Showa Denko K.K., Tokyo, JP. (C22C 21/00, PS
60 2006 017 415, EP 1939312, WO 2007/026481,
AT: 25.07.2006, EP-AT: 25.07.2006, WO-AT:
25.07.2006)
Bodenflächenelement sowie Bodenfläche und
Verwendung einer Bodenfläche. Alcan Centre de Recherches de Voreppe, F-38341 Voreppe
Cedex, FR. (E04F 15/06, EPA 2372040, EP-AT:
25.03.2011, WO-AT: 25.03.2011)
Lagerlegierung auf Aluminiumbasis und Verfahren zu deren Herstellung. Daido Metal Co.,
Ltd., Nagoya, JP. (C22C 21/04, OS 10 2011 075
580, AT: 10.05.2011)
Geschäumte Kunststoffplatte. Alcan Technology & Management Ltd., Neuhausen am Rheinfall,
CH. (B32B 3/18, PS 503 03 984, EP 1536944,
WO 2004/024434, AT: 16.08.2003, EP-AT:
16.08.2003, WO-AT: 16.08.2003)
Bearbeitetes Produkt mit optischem Sensor
und Herstellungsverfahren dafür. Alcan Rhenalu, Courbevoie, FR. (B21C 23/22, PS 60 2008
003 200, EP 2125259, WO 2008/129178,
AT: 18.03.2008, EP-AT: 18.03.2008, WO-AT:
18.03.2008)
Verfahren zur Herstellung von Konstruktionselementen durch maschinelle Bearbeitung dicker Platten. Alcan Rhenalu, Paris, FR. (C22F 1/
00, PS 603 34 731, EP 1573080, WO 2004/
056501, AT: 17.12.2003, EP-AT: 17.12.2003,
WO-AT: 17.12.2003)
Längliches Halteelement. Corus Bausysteme
GmbH, 56070 Koblenz, DE. (E04D 3/362, GM
203 80 217, WO 2004/022877, AT: 29.08.2003,
WO-AT: 29.08.2003)
Verfahren zum Herstellen eines Hohlprofils.
Aleris Aluminum Koblenz GmbH, 56070 Koblenz,
DE; Daimler AG, 70327 Stuttgart, DE. (B21C
37/08, OS 10 2010 018 504, AT: 28.04.2010)
Verfahren zur Herstellung einer Baustrebe
durch Crimpen und so erhaltene Baustrebe.
Norsk Hydro ASA, 0240 Oslo, NO. (E06B 3/273,
EP 2 055 883, EP-AT: 23.10.2008, WO-AT:
23.10.2008)
Vorrichtung zum Befüllen einer Schwerkraftgießform mit einer flüssigen Schmelze. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B22C 9/08, PS 10 2010 010 322, AT:
04.03.2010)
90
Profilanordnung und Einfassprofil für eine Profilanordnung. MayTec Aluminium Systemtechnik GmbH, 85221 Dachau, DE. (F16B 5/06, GM
203 21 258, AT: 24.04.2003)
Verbindungsvorrichtung zum schrägen Verbinden eines Hohlprofils mit einem weiteren Profil quer zu dessen Längsrichtung. MayTec Aluminium Systemtechnik GmbH, 85221 Dachau,
DE. (F16B 7/04, GM 203 21 707, AT: 24.04.2003)
Verbindungsvorrichtung
zum
Verbinden
eines Hohlprofils mit einem weiteren Profil.
MayTec Aluminium Systemtechnik GmbH, 85221
Dachau, DE. (F16B 7/04, GM 203 21 709, AT:
24.04.2003)
Hochfeste, schweißbare Al-Mg-Legierung. Aleris Aluminum Koblenz GmbH, 56070 Koblenz,
DE. (C22C 21/06, EP 1 917 373, WO 2007/
020041, AT: 14.08.2006, EP-AT: 14.08.2006,
WO-AT: 14.08.2006)
Verfahren zur Herstellung eines Bauteiles und
Bauteile aus einer Titan-Aluminium-Basislegierung. Böhler Schmiedetechnik GmbH & Co. KG,
8605 Kapfenberg, AT. (C22C 1/04, EPA 2386663,
EP-AT: 26.04.2011, WO-AT: 26.04.2011)
Verfahren zum flusslosen Löten von Aluminium und Lötblech zur Verwendung darin. Aleris
Aluminum Koblenz GmbH, 56070 Koblenz, DE.
(B32B 15/01, EPA 2382087, WO 2010/052231,
EP-AT: 04.11.2009, WO-AT: 04.11.2009)
System zur Produktion von hoch isolierenden
Fenster- und Türrahmen aus einem AluminiumHolz-Gemisch. DFV S.R.L., 73030 Surano (LE), IT.
(E06B 3/30, EPA 2385207, EP-AT: 14.02.2011,
WO-AT: 14.02.2011)
Korrosionsschutzschicht für Al- und Mg-Legierungen. EADS Deutschland GmbH, 85521 Ottobrunn, DE; TU Wien, 1040 Wien, AT. (C08G
77/26, EPA 2379623, WO 2010/081757, EP-AT:
07.01.2010, WO-AT: 07.01.2010)
Produkte aus einer Aluminium-Kupfer-Lithium-Legierung. Constellium France, 92400
Courbevoie, FR. (C22C 21/00, EPA 2364378,
WO 2010/055225, EP-AT: 10.11.2009, WO-AT:
10.11.2009)
Vorrichtung zur Sicherung von als Paket gelagerten Aluminium-Stranggussprodukten, sog.
Masseln, zu Transportzwecken. Signode System
GmbH, 46535 Dinslaken, DE. (B65D 85/20, GM
20 2006 012 782, AT: 21.08.2006)
Fenster- und/oder Türflügelelement bestehend
aus thermisch getrennten Aluminium-Hohlkammerprofilen mit eingefassten Glasscheiben. heroal – Johann Henkenjohann GmbH &
Co. KG, 33415 Verl, DE. (E06B 3/42, GM 20 2010
008 622, AT: 24.09.2010)
Kohlenstoffmaterial in Aluminium. Dayou
Smart Aluminium Co., Ltd., Seo, Gwangju, KR;
Sungkyunkwan University Foundation for Corporate Collaboration, Suwon, Kyonggi, KR. C23C
26/00, PS 60 2008 003 181, EP 2072635, AT:
24.07.2008, EP-AT: 24.07.2008)
Verfahren zum Herstellen eines Aluminium-Dotierungsprofils. Infineon Technologies AG, 85579
Neubiberg, DE. (H01L 21/225, OS 593 07 362, EP
0560085, AT: 15.02.1993, EP-AT: 15.02.1993)
Verbundmaterial auf Aluminiumbasis und Verfahren zu dessen Herstellung. Honda Motor
Co., Ltd., Tokio, JP. (C22C 1/10, PS 11 2005 003
373, WO 2006/075431, AT: 26.10.2005, WOAT: 26.10.2005)
Schweißbares Strukturbauteil aus einer Aluminiumlegierung. Aleris Aluminum Koblenz
GmbH, 56070 Koblenz, DE. (B32B 15/01, EP 1
169 177, WO 2000/054967, AT: 17.03.2000, EPAT: 17.03.2000, WO-AT: 17.03.2000)
Patentblatt Dezember 2011
Al-Ti-Ru-N-C-Hartstoffschicht. Ceratizit Austria
Ges.m.b.H., Reutte, Tirol, AT. (C23C 16/30, PS
50 2008 001 850, EP 2179073, WO 2009/003206,
AT: 26.06.2008, EP-AT: 26.06.2008, WO-AT:
26.06.2008)
Aluminiumschnalle für Tragegurte. Stührmann,
Jan-Marc, 28211 Bremen, DE. (A44B 11/04, GM
20 2005 016 661, AT: 21.10.2005)
Aluminium-Werkstoff für Rohre von Kraftfahrzeug-Wärmetauschern. Furukawa-Sky Aluminium Corp., Tokio, JP. (C22C 21/00, PS 60 2007
010 872, EP 1892308, AT: 23.08.2007, EP-AT:
23.08.2007)
Verfahren zum Herstellen eines Gegenstandes
aus Metall, insb. aus einer hochfesten Aluminiumlegierung sowie Verfahren zum Richten
eines solchen Gegenstandes. Otto Fuchs KG,
58540 Meinerzhagen, DE. (B23P 13/00, PS 10
2008 003 882, AT: 10.01.2008)
PAT E N T E
Erdbohrdrehbohrmeißel mit Meißelkörpern,
die Borkarbidteilchen in Aluminium oder Legierungsmatrixmaterialien auf Aluminiumbasis aufweisen sowie Verfahren zur Herstellung
solcher Meißel. Baker Hughes Inc., Houston,
Tex., US. (E21B 10/42, EP 2 079 898, WO
2008/042328,AT: 28.09.2007,EP-AT: 28.09.2007,
WO-AT: 28.09.2007)
Vorrichtung und Verfahren zur Entfernung
von Kaffeesatz aus speziellen Kaffeekapseln
aus Aluminium und zur Verkleinerung dieser
Kapseln. Franssen, Guy-Jacques-Marie, Spa,
BE. (A47J, EP 2 146 608, WO 2008/139322,
AT: 23.04.2008, EP-AT: 23.04.2008, WO-AT:
23.04.2008)
Verfahren zur Herstellung einer Aluminiumlegierung. Nippon Light Metal, Co., Ltd., Shinagawa-ku, Tokio 140-8628, JP. (C22C 1/02, EPA
2379759, WO 2010/079677, EP-AT: 10.12.2009,
WO-AT: 10.12.2009)
Aluminiumlegierung für einen Gussmotorblock, Gusszylinderblock für einen Verbrennungsmotor sowie Verwendung der Aluminiumlegierung. General Motors Corp., Detroit,
Mich., US. (C22C 21/02, PS 11 2004 001 160,
WO 2005/010224, AT: 26.03.2004, WO-AT:
26.03.2004)
Schmiedekolben aus Aluminiumlegierung. Pechiney Aviatube, Carquefou, FR. (C22C 21/02,
GM 20 2005 014 834, AT: 20.09.2005)
Metallschäume aus einer Aluminiumlegierung,
ihre Verwendung und Verfahren zur Herstellung. Helmholtz-Zentrum Berlin für Materialien
und Energie GmbH, 14109 Berlin, DE. (C22C
1/08, EP 2 143 809, AT: 09.06.2009, EP-AT:
09.06.2009)
Verfahren zur Herstellung von hochfesten
Aluminiumlegierungen, die intermetallische
L12-Dispersoide enthalten. United Technologies
Corp., Hartford, CT 06101, US. (B22F 3/02, EPA
2385884, WO 2010/077735, EP-AT: 09.12.2009,
WO-AT: 09.12.2009)
Schweißbare,
hochfeste
Aluminiumlegierungen. The Boeing Company, Chicago, IL
60606-2016, US. (C22C 21/06, EPA 2384373,
WO 2010/080661, EP-AT: 23.12.2009, WO-AT:
23.12.2009)
Aluminiumlegierungen, Aluminiumlegierungsprodukte und Herstellungsverfahren dafür.
Alcoa Inc., Pittsburgh, PA 15212-5858, US. (C22C
21/00, EPA 2382334, WO 2010/083245, EP-AT:
13.01.2010, WO-AT: 13.01.2010)
Sandgießverfahren zur Herstellung von Bauteilen aus Magnesium- oder Aluminiumlegierungen. Rolls-Royce Deutschland Ltd. & Co. KG,
15827 Blankenfelde, DE. (B22D 27/08, OS 10
2010 025 061, AT: 25.06.2010)
Bodenflächenelement sowie Bodenfläche und
Verwendung einer Bodenfläche. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH. (E04F 15/06, OS 10 2010 013 918, AT:
01.04.2010)
L12-verstärkte amorphe Aluminiumlegierungen. United Technologies Corporation, Hartford, Conn., US. (C22C 21/00, EP 2 112 241, AT:
31.03.2009, EP-AT: 31.03.2009)
Schutzgaszusammensetzung für geschmolzene Nichteisenmetalle wie Magnesium. Honeywell International Inc., Morristown, N.J., US.
(C22B 9/00, EP 2 038 439, WO 2008/005920,
AT: 02.07.2007, EP-AT: 02.07.2007, WO-AT:
02.07.2007)
Legierung auf Magnesiumbasis mit verbesserter Fluidität und Heißreißfestigkeit und Herstellungsverfahren dafür. Korean Institute of Industrial Technology, Cheonan-si Chungcheongnamdo 331-825, KR. (C22C 23/00, EPA 2381002,
EP-AT: 24.03.2011, WO-AT: 24.03.2011)
Verfahren und System zur Überwachung des
Betriebes einer Kohlenstoffblockbrennanlage. Rio Tinto Alcan International Ltd., Montreal,
QC H3A 3G2, CA. (F27B 13/14, EPA 2379974,
WO 2010/072907, EP-AT: 08.12.2009, WO-AT:
08.12.2009)
Zelle zur Elektrogewinnung von Metallen mit
Elektrolytreiniger. Rio Tinto Alcan International
Ltd., Montreal, Quebec, CA. (C25C 3/06, EP 1
654 401, WO 2005/017234, AT: 10.08.2004, EPAT: 10.08.2004, WO-AT: 10.08.2004)
Verfahren zur Herstellung von grobkörnigem
Aluminiumhydroxyd. Rio Tinto Alcan International Ltd., Montreal, CA. (C01F 7/14, OS 698
36 962, EPA 0997435, AT: 28.10.1998, EP-AT:
28.10.1998)
Fußgängersichere Motorhaube mit Verstärkungsschaumstoff. Alcoa Inc., Pittsburgh, Pa.,
US. (B62D 25/10, PS 60 2008 003 413, EP
2121419, WO 2008/109811, AT: 07.03.2008,
EP-AT: 07.03.2008, WO-AT: 07.03.2008)
Beschichtetes Fahrzeugrad und Verfahren.
Alcoa Inc., Pittsburgh, Pa., US. (B05D 1/36, PS
603 35 657, EP 1578540, WO 2004/028833,
AT: 25.09.2003, EP-AT: 25.09.2003, WO-AT:
25.09.2003)
Verfahren zur Herstellung eines Aluminiumlegierungsplattenprodukts mit niedriger Restspannung. Aleris Aluminum Koblenz GmbH,
56070 Koblenz, DE. (C22F 1/04, EPA 2379765,
WO 2010/081889, EP-AT: 15.01.2010, WO-AT:
15.01.2010)
Verfahren zur Herstellung eines wärmegedämmten Verbundprofils. Norsk Hydro ASA,
Oslo, NO. (E06B 3/263, PS 10 2009 054 178, AT:
21.11.2009)
Lamellenanordnung für Fassaden. Norsk Hydro
ASA, Oslo, NO. (E04F 10/08, EP 1 816 279, AT:
27.01.2007, EP-AT: 27.01.2007)
Horizontal stranggegossener Aluminiumlegierungsstab und Verfahren und Vorrichtung
zur Herstellung des Stabs. Showa Denko K.K.,
Tokio, JP. (B22D 11/16, OS 11 2004 000 509,
WO 2004/085096, AT: 26.03.2004, WO-AT:
26.03.2004)
Tür oder Fenster mit seitlicher Führung des
freien Randes einer zentralen Dichtungsverbindung. Norsk Hydro ASA, Oslo, NO. (E06B
7/22, PS 60 2008 003 600, EP 1972749, AT:
22.02.2008, EP-AT: 22.02.2008)
Koaxialprofil. Erbslöh Aluminium GmbH, 42553
Velbert, DE. (F16L 9/02, GM 20 2008 006 379,
AT: 09.05.2008)
Vorrichtung zur Halterung von Bauteilen. Erbslöh AG, 42553 Velbert, DE. (F16M 11/20, GM 20
2010 007 497, AT: 02.06.2010)
Korrosionsgeschütztes System für einen
Wärmetauscher. Erbslöh Aluminium GmbH,
42553 Velbert, DE. (B23K 1/19, GM 20 2011 101
606, AT: 09.06.2011)
Regenschutzschiene. Gutmann AG, 91781 Weißenburg, DE. (E06B 1/34, GM 20 2008 014 277,
AT: 27.10.2008)
Verfahren zur Herstellung eines Kolbens einer
Brennkraftmaschine. KS Kolbenschmidt GmbH,
74172 Neckarsulm, DE. (B23P 15/10, PS 10 2008
034 428, AT: 24.07.2008)
Verfahren zur Herstellung eines Kolbens für einen Verbrennungsmotor. Mahle GmbH, 70376
Stuttgart, DE. (B23P 15/10, OS 10 2004 056 519,
AT: 24.11.2004)
Kolben mit einem Kühlkanal für einen Verbrennungsmotor und Verfahren zur Herstellung
des Kolbens. Mahle International GmbH, 70376
Stuttgart, DE. (F02F 3/22, OS 10 2004 056 870,
AT: 25.11.2004)
Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/26, OS 10 2004 057 625, AT:
30.11.2004)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/22 u. F16J 1/00 , OS 10 2010 025 507 u. OS 10
2010 025 508 , AT: 29.06.2010)
Gebauter Kolben für einen Verbrennungsmotor. Mahle GmbH, 70376 Stuttgart, DE. (F02F 3/00,
PS 50 2005 010 583, EP 1761697, WO 2005/
124137, AT: 20.06.2005, EP-AT: 20.06.2005,
WO-AT: 20.06.2005)
Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, PS 50 2006 008 456, EP
1960653, WO 2007/068222, AT: 07.06.2006,
EP-AT: 07.06.2006, WO-AT: 07.06.2006)
Kolben. Mahle König Kommanditgesellschaft
GmbH & Co., Rankweil, AT. (F02F 3/24, EP 2 167
806, WO 2009/006650, AT: 27.03.2008, EP-AT:
27.03.2008, WO-AT: 27.03.2008)
Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, EP 2 189 644, AT: 13.11.
2009, EP-AT: 13.11.2009)
Fortsetzung in ALUMINIUM 3/2012
91
/,()(59(5=(,&+1,6
1
Smelting technology
Hüttentechnik
1.1 Raw materials
1.2 Storage facilities for smelting
1.3 Anode production
1.4 Anode rodding
1.4.1 Anode baking
1.4.2 Anode clearing
1.4.3 Fixing of new anodes to the
anodes bars
1.5 Casthouse (foundry)
1.6 Casting machines
1.7 Current supply
1.8 Electrolysis cell (pot)
1.9 Potroom
1.10 Laboratory
1.11 Emptying the cathode shell
1.12 Cathode repair shop
1.13 Second-hand plant
1.14 Aluminium alloys
1.15 Storage and transport
1.16 Smelting manufactures
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
E-Mail: [email protected]
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
1.1 Rohstoffe
1.2 Lagermöglichkeiten in der Hütte
1.3 Anodenherstellung
1.4 Anodenschlägerei
1.4.1 Anodenbrennen
1.4.2 Anodenschlägerei
1.4.3 Befestigen von neuen Anoden
an der Anodenstange
1.5 Gießerei
1.6 Gießmaschinen
1.7 Stromversorgung
1.8 Elektrolyseofen
1.9 Elektrolysehalle
1.10 Labor
1.11 Ofenwannenentleeren
1.12 Kathodenreparaturwerkstatt
1.13 Gebrauchtanlagen
1.14 Aluminiumlegierungen
1.15 Lager und Transport
1.16 Hüttenerzeugnisse
1.3 Anode production
Anodenherstellung
Solios Carbone – France
www.fivesgroup.com
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
A
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | [email protected]
Auto firing systems
Automatische Feuerungssysteme
Anode Technology &
Mixing Equipment
Buss ChemTech AG, Switzerland
Phone:
+4161 825 64 62
E-Mail:
[email protected]
Internet: www.buss-ct.com
www.alu-web.de
Mixing Technology for
Anode pastes
Mischtechnologie für Anodenmassen
www.coperion.com
mailto: [email protected]
Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
Internet: www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
Unloading/Loading equipment
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
Internet: www.riedhammer.de
Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
Buss AG
CH-4133 Pratteln
Phone:
+41 61 825 66 00
E-Mail:
[email protected]
Internet: www.busscorp.com
Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
Entlade-/Beladeeinrichtungen
www.flsmidthmoeller.com
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, [email protected]
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone:
+352 27612 0
Fax:
+352 27612 109
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
Internet: www.riedhammer.de
$/80,1,80³
6833/,(56',5(&725<
Melting/holding/casting furnaces
1.4 Anode rodding
Schmelz-/Halte- und Gießöfen
Anodenanschlägerei
Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
1.4.1 Anode baking
Anodenbrennen
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
Internet: www.hertwich.com
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
Internet: www.inotherm-gmbh.de
Gautschi
Engineering GmbH
see Casting equipment 3.1
Solios Thermal UK
www.fivesgroup.com
see Casthouse (foundry) 1.5
Anode charging/Anodenchargieren
SERMAS INDUSTRIE
see Casting Machines 1.6
Anode storage/Anodenlager
SERMAS INDUSTRIE
see Equipment and accessories 3.1
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
Internet: www.stopinc.ch
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y
Y.Dudullu,
TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
1.4.2 Anode clearing
Anodenschlägerei
Separation of spent anodes
from the anode bars
Trennen von den Anodenstangen
SERMAS INDUSTRIE
1.4.3 Fixing of new anodes
to the anodes bars
Befestigen von neuen
Anoden a. d. Anodenstange
Fixing the nipples to the
anodes by casting in
Befestigen der Nippel mit der
Anode durch Eingießen
Degassing, filtration and
grain refinement
Gautschi
Engineering GmbH
Entgasung, Filtern, Kornfeinung
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
Dross skimming of liquid metal
Abkrätzen des Flüssigmetalls
Transfer to the casting furnace
Überführung in Gießofen
see Anode rodding 1.4
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
SERMAS INDUSTRIE
Gautschi
Engineering GmbH
1.5 Casthouse (foundry)
see Casting machines 1.6
Transport of liquid metal
to the casthouse
Gießerei
Transport v. Flüssigmetall in Gießereien
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
www.mechatherm.com
$/80,1,80³
Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
/,()(59(5=(,&+1,6
Treatment of casthouse
off gases
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
Scales / Waagen
Gautschi
Engineering GmbH
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
Internet: www.wagstaff.com
1.8 Electrolysis cell (pot)
Gießmaschinen
GAPCast : the Swiss casting solution
see Casting machines and equipment 4.7
TM
www.alu-web.de
Elektrolyseofen
Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
Sawing / Sägen
www.mechatherm.com
see Smelting technology 1.5
Gautschi
Engineering GmbH
www.coperion.com
mailto: [email protected]
Calcium silicate boards
Calciumsilikatplatten
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
RIHS ENGINEERING SA
see Casting machines and equipment 4.7
Pig casting machines (sow casters)
Abgasbehandlung
Masselgießmaschine (Sowcaster)
Gautschi
Engineering GmbH
Rolling and extrusion ingot
and T-bars
Solios Environnement
www.fivesgroup.com
343 Chemin du Stade
38210 Saint Quentin sur Isère
Tel. +33 (0) 476 074 242
Fax +33 (0) 476 936 776
Internet: www.sermas.com
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
Engineering GmbH
Exhaust gas treatment
Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
www.flsmidthmoeller.com
1.9 Potroom
Elektrolysehalle
T T.
T.
T Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
Contact: Giovanni Magarotto
Horizontal continuous casting
Anode transport equipment
see Billet Heating Furnaces 1.5
Vertical semi-continuous DC
casting / Vertikales Stranggießen
Anodenwechselmaschine
Horizontales Stranggießen
Gautschi
Engineering GmbH
Anode changing machine
Gautschi
Engineering GmbH
Anoden Transporteinrichtungen
Crustbreakers / Krustenbrecher
$/80,1,80³
6833/,(56',5(&725<
Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Environnement
www.fivesgroup.com
Tapping vehicles/Schöpffahrzeuge
www.alu-web.de
2
1.11 Emptying the cathode shell
Ofenwannenentleeren
1.14 Aluminium Alloys
Aluminiumlegierungen
Cathode bar casting units
Kathodenbarreneingießanlage
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
RHEINFELDEN ALLOYS GmbH & Co. KG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
Internet: www.rheinfelden-alloys.eu
1.15 Storage and transport
Lager und Transport
SMS Siemag
g AG
see Rolling mill technology 3.0
Extrusion
Strangpressen
2.1 Extrusion billet preparation
2.1.1 Extrusion billet production
2.2 Extrusion equipment
2.3 Section handling
2.4 Heat treatment
2.5 Measurement and control equipment
2.6 Die preparation and care
2.7 Second-hand extrusion plant
2.8 Consultancy, expert opinion
2.9 Surface finishing of sections
2.10 Machining of sections
2.11 Equipment and accessories
2.12 Services
2.1 Pressbolzenbereitstellung
2.1.1 Pressbolzenherstellung
2.2 Strangpresseinrichtungen
2.3 Profilhandling
2.4 Wärmebehandlung
2.5 Mess- und Regeleinrichtungen
2.6 Werkzeugbereitstellung und -pflege
2.7 Gebrauchte Strangpressanlagen
2.8 Beratung, Gutachten
2.9 Oberflächenveredlung von Profilen
2.10 Profilbearbeitung
2.11 Ausrüstungen und Hilfsmittel
2.12 Dienstleistungen
2.1 Extrusion billet preparation
2.1.1 Extrusion billet
production
Pressbolzenbereitstellung
Pressbolzenherstellung
mfw-maschinenbau.com
• Log/Bolzenlager Handling
• Bolzensäge, Bolzenfügen
Billet heating furnaces
MARX GmbH & Co. KG
www.marx-gmbh.de
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
Billet transport and storage
equipment
Bolzen-Transport- u. Lagereinricht.
SERMAS INDUSTRIE
See Casting Machines 1.6
2.2 Extrusion equipment
Strangpresseinrichtungen
Öfen zur Bolzenerwärmung
www.mechatherm.com
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
$/80,1,80³
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y Dudullu, TR-34775 Istanbul/Turkey
Y.
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
Internet: www.oilgear.de
/,()(59(5=(,&+1,6
SMS Meer GmbH
see Extrusion equipment 2.2
SMS Meer GmbH
Schloemann Extrusion
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Tel. +49 (0) 2161 350-0
Fax +49 (0) 2161 350-1667
Internet: www.sms-meer.com
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
Internet: www.herrmannhieber.de
Verpackungseinrichtungen
SMS Meer GmbH
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
CTI Systems S.A.
Z.I. Eselborn – Lentzweiler
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Internet: www.ctisystems.com
SMS Meer GmbH
www.alu-web.de
Temperaturmessung
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
[email protected] / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
Temperature measurement
Profil-Lagereinrichtungen
Packaging equipment
Containers / Rezipienten
Press control systems
Section store equipment
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
Vollert Anlagenbau GmbH
see Packaging equipment 2.3
SMS Meer GmbH
Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
Stadtseestraße 12
D-74189 Weinsberg
Tel.
+49 (0) 7134 / 52-220
Fax
+49 (0) 7134 / 52-222
E-Mail [email protected]
Internet www.vollert.de
Section transport equipment
Profiltransporteinrichtungen
SMS Meer GmbH
Puller equipment
Ausziehvorrichtungen/Puller
SMS Meer GmbH
MARX GmbH & Co. KG
www.marx-gmbh.de
Section cooling
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Profilkühlung
2.3 Section handling
Profilhandling
SMS Meer GmbH
Stackers / Destackers
Stapler / Entstapler
Section saws
Profilsägen
$EHUOH$XWRPDWLRQ*PE+&R.*
Daimlerstraße 40
74211 Leingarten
Tel. 07131 9059-0, Fax 07131 9059-59
Internet: www.aberle-automation.com
• Kurzlängensäge automatisiert
• 7 und 14 m De- u. Stacker
• Kombianlagen
$/80,1,80³
6833/,(56',5(&725<
SMS Meer GmbH
www.mechatherm.com
Stretching equipment
Reckeinrichtungen
SMS Meer GmbH
Transport equipment for
extruded sections
Heat treatment furnaces
Wärmebehandlungsöfen
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
2.9 Surface finishing
of sections
Transporteinrichtungen
für Profilabschnitte
Oberflächenveredlung
von Profilen
Homogenising furnaces
Homogenisieröfen
• Strahlanlagen
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
• Skip Handling, Spacer
• Kettenförderer
2.4 Heat treatment
Wärmebehandlung
2.5 Measurement and
control equipment
Mess- und Regeleinrichtungen
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
www.alu-web.de
Extrusion plant control systems
Presswerkssteuerungen
SMS Meer GmbH
Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
2.6 Die preparation and care
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
[email protected] · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen
Werkzeugbereitstellung
und -pflege
Die heating furnaces
Werkzeuganwärmöfen
MARX GmbH & Co. KG
www.marx-gmbh.de
schwartz GmbH
$/80,1,80³
see Heat treatment 2.4
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
/,()(59(5=(,&+1,6
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Rolling mill technology
Walzwerktechnik
Casting equipment
Rolling bar machining
Rolling bar furnaces
Hot rolling equipment
Strip casting units and accessories
Cold rolling equipment
Thin strip / foil rolling plant
Auxiliary equipment
Adjustment devices
Process technology /
Automation technology
Coolant / lubricant preparation
Air extraction systems
Fire extinguishing units
Storage and dispatch
Second-hand rolling equipment
Coil storage systems
Strip Processing Lines
Productions Management Systems
3.0 Rolling mill technology
Walzwerktechnik
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Gießanlagen
Walzbarrenbearbeitung
Walzbarrenvorbereitung
Warmwalzanlagen
Bandgießanlagen und Zubehör
Kaltwalzanlagen
Feinband-/Folienwalzwerke
Nebeneinrichtungen
Adjustageeinrichtungen
Prozesstechnik /
Automatisierungstechnik
Kühl-/Schmiermittel-Aufbereitung
Abluftsysteme
Feuerlöschanlagen
Lagerung und Versand
Gebrauchtanlagen
Coil storage systems
Bandprozesslinien
Produktions Management Systeme
3.1 Casting equipment
Gießanlagen
see Cold rolling units / complete pllants 3.6
www.mechatherm.com
www.alu-web.de
Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
Internet: www.loi-italimpianti.com
Solios Thermal UK
www.fivesgroup.com
Melt purification units
Schmelzereinigungsanlagen
Gautschi
Engineering GmbH
Metal filters / Metallfilter
Wagstaff, Inc.
Melting and holding furnaces
Schmelz- und Warmhalteöfen
Gautschi
Engineering GmbH
3.2 Rolling bar machining
Walzbarrenbearbeitung
Band saws / Bandsägen
SMS Meer GmbH
Gautschi Engineering GmbH
Konstanzer Straße 37
CH 8274 Tägerwilen
Telefon +41 71 666 66 66
Telefax +41 71 666 66 77
Internet: www.gautschi.cc
Kontakt: Sales Departement
Slab milling machines
Barrenfräsmaschinen
SMS Meer GmbH
$/80,1,80³
6833/,(56',5(&725<
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
3.4 Hot rolling equipment
Warmwalzanlagen
3.6 Cold rolling equipment
Kaltwalzanlagen
g
see Heat Treatment 2.4
Annealing furnaces
Glühöfen
EBNER Industrieofenbau Ges.m.b.H.
Ebner-Platz 1, 4060 Leonding/Austria
Tel. +43 / 732 / 6868-0
Internet: www.ebner.cc
Gautschi
Engineering GmbH
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
Coil transport systems
Bundtransportsysteme
see Heat Treatment 2.4
www.alu-web.de
Coil annealing furnaces
Bundglühöfen
schwartz GmbH
Solios Thermal UK
www.fivesgroup.com
Bar heating furnaces
Barrenanwärmanlagen
Gautschi
Engineering GmbH
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
schwartz GmbH
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
Homogenising furnaces
Homogenisieröfen
Coil transport systems
Bundtransportsysteme
Drive systems / Antriebe
SMS Siemag
g AG
Gautschi
Engineering GmbH
Rolling mill modernisation
Walzwerksmodernisierung
SMS Siemag
g AG
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
schwartz GmbH
Spools / Haspel
SMS Siemag
g AG
Solios Thermal UK
www.fivesgroup.com
Roller tracks
Rollengänge
Gautschi
Engineering GmbH
$/80,1,80³
Hot rolling units /
complete plants
Rechbergstraße 46
Tel. +49 711 93467-0, Fax +49 711 34609-11
Warmwalzanlagen/Komplettanlagen
SMS Siemag
g AG
/,()(59(5=(,&+1,6
Cold rolling units /
complete plants
Strip shears/Bandscheren
Kaltwalzanlagen/Komplettanlagen
SMS Siemag
g AG
Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
SMS Siemag
g AG
SMS Siemag
g AG
Trimming equipment
Besäumeinrichtungen
Rolling mill modernization
Walzwerkmodernisierung
Drive systems / Antriebe
SMS Siemag
g AG
Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
schwartz GmbH
SMS Siemag
g AG
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
SMS Siemag
g AG
Coil annealing furnaces
Kabelummantelungspressen
SMS Meer GmbH
Bundglühöfen
Roll exchange equipment
SMS Meer GmbH
Cable sheathing presses
Prozesssimulation
Gautschi
Engineering GmbH
Adjustageeinrichtungen
Blech- und Plattenstrecker
Prozessoptimierungssysteme
Process simulation
3.9 Adjustment devices
Sheet and plate stretchers
Process optimisation systems
Gautschi
Engineering GmbH
Gautschi
Engineering GmbH
Walzenwechseleinrichtungen
Cable undulating machines
Kabelwellmaschinen
SMS Meer GmbH
SMS Siemag
g AG
Transverse cutting units
Querteilanlagen
Rolling mill modernization
Walzwerkmodernisierung
schwartz GmbH
see Cold colling equipment 3.6
Heating furnaces
Anwärmöfen
Gautschi
Engineering GmbH
SERMAS INDUSTRIE
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
Process control technology
Prozessleittechnik
SMS Siemag
g AG
Slitting lines-CTL
Längs- und Querteilanlagen
Wagstaff, Inc.
$/80,1,80³
6833/,(56',5(&725<
Strip flatness measurement
and control equipment
Roll Force Measurement equipment
Walzkraftmesseinrichtungen
Bandplanheitsmess- und
-regeleinrichtungen
3.12 Air extraction systems
Abluft-Systeme
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
Internet: www.abb.com/pressductor
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
SMS Siemag
g AG
SMS Siemag
g AG
Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
3.14 Storage and dispatch
Lagerung und Versand
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
SMS Siemag
g AG
3.16 Coil storage systems
Bundlagersysteme
3.11 Coolant / lubricant
preparation
Kühl-/SchmiermittelAufbereitungg
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag
g AG
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
SMS Siemag
g AG
SMS Siemag
g AG
Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
Rolling oil rectification units
Walzölrektifikationsanlagen
3.17 Strip Processing Lines
Bandprozesslinien
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
$/80,1,80³
SMS Siemag
g AG
REDEX
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
Internet: www.tension-leveling.com
/,()(59(5=(,&+1,6
Colour Coating Lines
Strip Annealing Lines
Bandlackierlinien
www.bwg-online.com
see Strip Processing Lines 3.17
Bandglühlinien
3.18 Production
Management systems
Produktions Management
Systeme
www.bwg-online.com
Lithographic Sheet Lines
www.alu-web.de
Lithografielinien
www.bwg-online.com
Strip Processing Lines
PSI Metals Non Ferrous GmbH
Software Excellence in Metals
Carlo-Schmid-Str. 12, D-52146 Würselen
Tel.: +49 (0) 2405 4135-0
[email protected], www.psimetals.com
Bandprozesslinien
see Cold rolling units / complete plants 3.6
Stretch Levelling Lines
Streckrichtanlagen
www.bwg-online.com
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
Internet: www.bwg-online.com
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
4 Foundry
Gießerei
4.1 Work protection and ergonomics
4.2 Heat-resistant technology
4.3 Conveyor and storage technology
4.4 Mould and core production
4.5 Mould accessories and accessory materials
4.6 Foundry equipment
4.7 Casting machines and equipment
4.8 Handling technology
4.9 Construction and design
4.10 Measurement technology and materials testing
4.11 Metallic charge materials
4.12 Finshing of raw castings
4.13 Melt operations
4.14 Melt preparation
4.15 Melt treatment devices
4.16 Control and regulation technology
4.17 Environment protection and disposal
4.18 Dross recovery
4.19 Gussteile
4.2 Heat-resistent technology
Feuerfesttechnik
Refractories / Feuerfeststoffe
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Arbeitsschutz und Ergonomie
Feuerfesttechnik
Förder- und Lagertechnik
Form- und Kernherstellung
Formzubehör, Hilfsmittel
Gießereianlagen
Gießmaschinen und Gießeinrichtungen
Handhabungstechnik
Konstruktion und Design
Messtechnik und Materialprüfung
Metallische Einsatzstoffe
Rohgussnachbehandlung
Schmelzbetrieb
Schmelzvorbereitung
Schmelzebehandlungseinrichtungen
Steuerungs- und Regelungstechnik
Umweltschutz und Entsorgung
Schlackenrückgewinnung
Cast parts
4.3 Conveyor and storage
technology
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
4.3 Conveyor and storage
technology
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Rechbergstraße 46
Tel. +49 711 93467-0, Fax +49 711 34609-11
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
$/80,1,80³
6833/,(56',5(&725<
4.5 Mold accessories and
accessory materials
Formzubehör, Hilfmittel
4.8 Handling technology
www.mechatherm.com
Handhabungstechnik
Fluxes
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
4.6 Foundry equipment
Molten Metall Level Control
Ostra Hamnen 7
SE-430 91 Hono / Schweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
Internet: www.precimeter.com
Sales contact: Jan Strömbeck
Gießereianlagen
www.mechatherm.com
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
www.alu-web.de
Casting machines
Gießmaschinen
Manipulators
Manipulatoren
Competence in EMC and ASC casting
RIHS ENGINEERING SA
Tel.: +41 27 455 54 41
Internet: www.maschko.ch
4.11 Metallic charge
materials
Metallische Einsatzstoffe
Wagstaff, Inc.
Wärmebehandlungsöfen
Continuous ingot casting
lines and aluminium rod lines
ELPO GmbH
Kuchengrund 18
71522 Backnang
Telefon 07191 9572-0
Telefax 07191 9572-29
Internet: www.elpo.de
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPCast TM: the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
Internet: www.gap-engineering.ch
$/80,1,80³
SERMAS INDUSTRIE
Kokillengieß- und Aluminiumdraht-Anlagen
Via Emilia Km 310
26858 Sordio-LO
Tel. +39.02.988492-1
Fax +39.02.9810358
q p p
Internet: www.properzi.com
p p
Mould parting agents
Kokillentrennmittel
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
www.schroeder-schmierstoffe.de
Recycling / Recycling
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
WEIMA Maschinenbau GmbH
Internet: www.weima.com
4.13 Melt operations
Schmelzbetrieb
www.mechatherm.com
Wärmebehandlungsanlagen
/,()(59(5=(,&+1,6
Melting furnaces
4.15 Melt treatment devices
Schmelzöfen
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
Internet: www.bloomeng.de
Sales Contact: Tim Hennig
Melting furnaces
Schmelzbehandlungseinrichtungen
4.14 Melt preparation
Schmelzöfen
Gautschi
Engineering GmbH
Schmelzvorbereitung
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
Internet: www.metaullics.com
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
Degassing, filtration
Entgasung, Filtration
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
5
Dust removal
Entstaubung
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
Materials and Recycling
Werkstoffe und Recycling
Granulated aluminium
Aluminiumgranulate
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
Internet: www.marx-gmbh.de
WEIMA Maschinenbau GmbH
Internet: www.weima.com
www.alu-web.de
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
Holding furnaces
Warmhalteöfen
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
Internet: www.bloomeng.de
Sales Contact: Tim Hennig
6
Machining and Application
Bearbeitung und Anwendung
6.1 Surface treatment
processes
Prozesse für die
Oberflächenbehandlung
Henkel AG & Co. KGaA
siehe Prozesse für die Oberflächentechnik 6.1
Joining / Fügen
Gautschi
Engineering GmbH
Anodising / Anodisation
D-40191 Düsseldorf
Tel. +49 (0) 211 / 797-30 00
Fax +49 (0) 211 / 798-23 23
Internet: www.henkel-technologies.com
Cleaning / Reinigung
Wärmebehandlungsanlagen
Gautschi
Engineering GmbH
Adhesive bonding / Verkleben
Pretreatment before coating
Vorbehandlung vor der Beschichtung
$/80,1,80³
6833/,(56',5(&725<
6.2 Semi products
Halbzeuge
6.3 Equipment for forging
and impact extrusion
Wires / Drähte
Ausrüstung für Schmiedeund Fließpresstechnik
DRAHTWERK ELISENTAL
T
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
Internet: www.elisental.de
www.alu-web.de
International
ALUMINIUM
Journal
88. Jahrgang 1.1.2012
Verlag / Publishing house
V
Giesel Verlag GmbH
Postfach 5420, 30054 Hannover
Hans-Böckler-Allee
r
9, 30173 Hannover
Tel. 0511 7304-0, Fax 0511 7304-157
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Geschäftsleitung
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Tel. 0821 319880-34, [email protected]
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Jahresbezugspreis
EUR 289,- (Inland inkl. 7% MwSt. und Versandkosten). Europa EUR 289,- inkl. Versandkosten.
Einzelausgabe EUR 28,90. Übersee US$ 382,– inkl.
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Hydraulic Presses
8
Literature
Literatur
Technical literature
Fachliteratur
Hydraulische Pressen
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
Internet: www.lasco.com
gabe US$ 38,20. Preise für Studenten auf Anfrage.
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VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special:
Umschmelzen und Recycling von Aluminium
Special:
Remelting and recycling of aluminium
Wir berichten über Unternehmen und Ausrüster der
Umschmelz- und Recyclingbranche: über Maschinen und
Anlagen, neue Projekte und innovative Entwicklungen.
Beiträge unter anderem:
• Jasper GmbH: Innovative Entwicklungen an und
um den industriellen Ofenbau
• Vom volumenreichen Alu-Span zum kleinen Brikett
• Bartz Maschinenbau liefert komplettes
Schmelzwerk nach Frankreich
• Aktuelle IME-Forschungsprojekte zum Recycling
We will report on companies and equipment partners of the
remelt and recycling industry, with emphasis on new machines and plants, projects and technological developments.
Topics include:
• Jasper GmbH: Innovations and
developments for industrial furnaces
• From high-volume aluminium swarf
to compact briquettes
• Bartz supplies complete remelt plant to France
• Current research projects on
aluminium recycling at IME / RWTH Aachen
Weitere Themen
Other topics
• VAR/OEA Druckgusswettbewerb 2012 – die Gewinner
• E-Mobilität und ihre Auswirkungen auf die aluminiumverarbeitende Industrie und die Thermoprozesstechnik
Erscheinungstermin:
Anzeigenschluss:
Redaktionsschluss:
• VAR/OEA Die Casting Competition 2012 – the winners
• Latest news from the aluminium industry
12. März 2012
27. Februar 2012
20. Februar 2012
Date of publication:
Advertisement deadline:
Editorial deadline:
12 March 2012
27 February 2012
20 February 2012
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Being able to trust in the expertise and performance of
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customers around the world this means being able to count
on a comprehensive offering in the area of aluminum production. From thermal pre-treatment to shaping and refining, we
always meet the constantly rising challenges of the market.
Whether in new plant construction or revamp projects, our
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Confidence through performance – SMS Siemag.
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